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US English - Oce Display Graphics Systems Inc.

1. Fig 4 36 Define reference point gt Select the function Define reference2 1 1 3 gt Use the travel keys to move to the required reference point on the working area Choose OK to confirm Y The reference point is saved for the duration of time that the cutter is switched on This reference point now applies as the start point for the material processing 4 50 000010 09 11 2009 jmu G3 Series Controls and operation Material stop 4 11 Material stop Important Damage to tool inserts tools and modules Remove the material stop after positioning the processing material The material stop serves as an aid for positioning the processing material at the zero point Fig 4 37 Material stop 4 51 000010 09 11 2009 jmu Controls and operation G3 Series Module carriage slot protective plate 4 12 Module carriage slot protective plate Attention Risk of being crushed The module carriage area is not monitored by safety devices Do not reach into the active area of the cutter during operation Do not protect occupied slots with slot protective plates On the one hand the slot protective plate is used as a safety device and on the other it is used to protect a free module slot from contamination Two slot protective plates are supplied gb297 HA Fig 4 38 Slot protective plate 4 52 000010 09 11 2009 jmu
2. gb249 Fig 5 22 DIN test 255 mm x 170 mm 3 3 8 S Test Quality test gb248 Fig 5 23 S test 140 mm x 240 mm 3 3 9 Move line as for diagonal test except with limitation Define line Move to starting point choose OK to confirm Move to end point choose OK to confirm 3 3 11 Module 1 Switch module 1 on off On Module performs test Off Module does not perform test 5 37 000015 040 11 2009 jmu Description of menu G3 Series Description of menu 3 3 12 3 3 13 3 3 14 3 3 15 3 3 16 3 3 17 3 3 18 3 3 20 3 5 Module 2 Switch module 2 on off On Module performs test Off Module does not perform test Module 3 Switch module 3 on off On Module performs test Off Module does not perform test Module 4 Switch module 4 on off On Module performs test Off Module does not perform test Module 5 Switch module 5 on off On Module performs test Off Module does not perform test Module 6 Switch module 6 on off On Module performs test Off Module does not perform test Module 7 Switch module 7 on off On Module performs test Off Module does not perform test Module 8 Switch module 8 on off On Module performs test Off Module does not perform test PUM running in proc New PUM modules must undergo a running in procedure at customer s premises before being commissioned Dura
3. Item Sequence Description 1 Introduction The error group is started with the introduction sequence Error code 1 Display of the error code recorded first 3 Separator The display of the error is completed and another error follows Error code 2 Display of the next error code 5 Separator The display of the error is completed and another error follows Error code 3 Display of the next error code Conclusion The display of the group has been completed Error display If a number of errors occurred then the first error of this sequences is always shown on the display of the operating unit group All errors which have occurred after the confirmation of the last error are gathered together in a group Display last error group Use SHIFT _ Y _ ccc 2nd soft key to display all errors of the last group Display list of open errors While the first error is shown on the display SHIFT BY _ _ 1st soft key can be used to display a list with all open errors 6 2 000012 11 11 2009 jmu G3 Series Malfunctions 6 2 2 Locate error Error code The error code is made up of a 10 digit uniquely allocated combination of numbers and letters The signal word before the error code indicates how serious the error is Signal Error Information Important information for the operator Caution Notification of possible problems overheating Check status remedy errors contact the
4. 4 36 000010 09 11 2009 jmu G3 Series Controls and operation Material hold down 4 7 Material hold down The material is held down via a vacuum For this purpose the machine table is divided into 0 X vacuum zones The number of zones is dependent on the size of the cutter The width of the continuously active vacuum zone 0 is 470 mm the width of each additional vacuum zone which can be activated is approx 80 mm The first vacuum zone is positioned on the right hand side of the worktop all other zones can be sequentially switched on off from right to left The strength of the hold down can be adjusted and is regulated via the control panel Only set the hold down to be as strong as is necessary in order to save energy and so that the device is not overloaded The vacuum is generated for the hold down via a vacuum generator which is positioned under the cutter Depending on the size and the power requirement either a turbine vacuum generator or a gas ring vacuum pump is used for the G3 series Fig 4 25 Vacuum zones e g L 2500 4 37 000010 09 11 2009 jmu Controls and operation G3 Series Material hold down 4 7 1 Preparation Cover the excess vacuum surface in order to achieve optimum material hold down during the processing procedure Fig 4 26 Defining the vacuum range Material being processed 2 Covering the excess vacuum area gt If possible position the material to be pro
5. 25 Safety instructions for operators 0 2 0 eee 25 Safety precautions for service personnel 055 26 DISPO O ee ie ee ee e aes 26 Controls and operation 0 00 cece ee eee teens 1 Generals cake eed clea kia Sh ae oe ate ae hea ay oS 4 1 Safe working practices 0 0 eee 1 0 2 000017 03 06 2009 jmu G3 Series 000017 03 06 2009 jmu 4 3 COTOS ic eet ak Shai eee dare ad eM elie Bt r 2 4 3 1 CONO pamela oe a AER da ents ote 2 AIRT Operating UNE Sica ers 3 4 3 1 2 Navigation KeyS ee Dro ENERE EPAR VASSARE te tees 4 4 3 1 3 Numerical KeYS 2c es 4 4 3 1 4 FUNCHON KEYS area sas EErEE a ke Oe ag Faw Bese a eS 4 4 3 1 9 TIQVOlKOVS erorrek eden ee ea de do 5 BIMO SOM KOS EEE ERTE at Ok E ae a AA Rot cake 5 4 3 1 7 Special keys ShortcutS 0 ee 6 4 3 2 Emergency stop switches 0 000 cee 7 4 3 3 Maintenance unit c cooocccococor ee bee ee 9 43 4 Interfaces a ev hee ee eh ee ee ee ee ee ev eed 10 4 4 Menu navigation secati deden an e e eee 11 4 4 1 Menus and functions naaus aaua aaa aeaa a eae 11 FAZ He eere A Ase Wh Gi SETA eae ata RS 13 FAS Momeni weak r le a Mee ee betes 13 444 Popups dialogues 00 00 c cee 13 4 4 5 User level oe sie a ade Ale ne a bad ees eee es bok 14 4 4 6 Function keys 0 0c eee eee 15 4 5 FUNGCUONS 0 niae a daa ddr 16 451 Set language er eeng EE ave PR Ada oe Eee 16 4 5 2 Sebdisplay t
6. HP GL f Sending the HP GL data to the cutter Processing the sent data 000003 06 11 2009 jmu Product description G3 Series Technical description 2 7 3 Complete machine Table vacuum plate The work surface is designed as a perforated sheet Vacuum zones are arranged under this perforated sheet which are connected to a high performance vacuum generator via a distributor The vacuum is used for holding down and tightening the material to be processed The cutter control permits sequential activation deactivation of the individual vacuum zones and therefore reduces energy consumption The vacuum generator turbine vacuum generator vacuum pump automatically regulates the vacuum strength 100 mBar Electronics unit The electronics unit is housed in the front right hand side of the cutter and is only accessible for service personnel via a removable cover The cutter control is housed in the electronics unit Power unit The power unit is housed in the rear right hand side of the cutter and is only accessible for service personnel via a removable cover The power unit contains the power supply of the complete cutter and is activated deactivated using an on off switch The connection of the individual consumers takes place using software control if required Pneumatics Air pressure and air flow are adjusted for the respective consumer via a maintenance unit The maintenance unit is acc
7. Safety signs Eye protection required Savety gloves required Fig 3 5 Safety signs 1 Danger of hand injuries Warning of the danger of cuts 3 Laser beam warning 4 2 Danger of electrical safety hazard 5 Wear eye protection 6 Wear protective gloves 7 Danger of electrical safety hazard Important safety signs on the machine must be followed Otherwise this could result in serious injuries or death Warning Safety risks due to missing or illegible safety signs Check all safety signs on a regular basis for legibility and completeness Replace missing or illegible safety signs promptly with new original signs Meaning of safety signs The symbols on the safety signs have specific meanings are located wherever certain behaviour is prohibited due to it being potentially dangerous Wear eye protection Wear protective gloves Crush hazard Keep hands clear of moving parts Danger of hand injuries crushing Moving parts can crush and cut Keep hands out of moving mechanism Danger of hand injuries severing Hazardous power inside Disconnect all power supplies before servicing Service by trained personnel only Hazardous power inside Service by trained personnel only NY Warning of electrical risk disconnect the device from the mains before ow carrying out maintenance access only for trained personnel A Warning of electrical risk access only for
8. 7 29 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs Front CE CE2500 and CE3200 7 30 G3 Series Cleaning and maintenance Maintenance jobs Front CE CE0800 CE1250 and CE1600 and rear CE CE2500 and CE3200 Front CE CE0800 CE1250 and CE1600 and rear CE CE0800 CE1250 and CE1600 1 Conveyor belt guides 3 Guide rollers on the feet 2 Guide rollers Important Turn on the vacuum when feeding through the conveyor belt to prevent it slipping Feed through the conveyor belt as shown in the corresponding illustration 7 31 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs Gluing the conveyor belt Attention Toxic fumes Do not breath in glue fumes e Only use glue in well ventilated rooms Attention Skin bonding or being irritated by glue Do not allow glue to come into contact with skin Do not ingest glue or allow to come into contact with mucous membranes Use chemical proof protective gloves when gluing the conveyor belt Fig 7 20 Overview gluing the conveyor belt 1 Assembly base A 25mm 2 Masking tape layer 1 B 0 5 mm 3 Staples C 10mm 4 Masking tape layer 2 D 15mm 5 Gap 6 Conveyor belt 7 32 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs Fig 7 21 Gluing the conveyor belt 7 33
9. Contact Service Please insert the PUM into another slot Contact Service The received front end command does not correspond to the syntax Error with com mand 2s Contact Service This front end command is not permitted in this status 2s Contact Service OptionBoard Str1A not available The external feed stop has therefore been deac tivated Contact Service 6 32 000012 11 11 2009 jmu G3 Series Malfunctions 0x00023403 0x00023703 0x00023801 0x00023902 0x00023A02 0x00023B02 0x00023C02 0x00023D04 0x00023E03 0x00024103 0x00024203 Error messages The external feed stop is active Contact Service The router converter is switched off Switch it on using the standby key or via the router menu The model of the universal unwinding unit has been changed The change will only take effect once the machine has been restarted It is recommended to restart the plotter before using the unwinding unit Park pos has been reached The AKI sensor has not been interrupted during upwards movement Contact Service The suction unit is blocking the Z axis The router height cannot be reached No official software release loaded Contact Service Another OptAnt is already installed in this slot Contact Service An error was found during the amplifier test Index 0x 0s Contact Service Router module is not linked with the FU System error Index 1 0s Index 2 1
10. 0x0001BF02 0x0001C003 0x0001C102 0x0001C203 Error messages Contact service Setup object not available Contact service No tool object available Contact service Virtual HAL object is already being used by another application eHALldent 0s Contact service Hardware not available Contact service Error in the user data command Cmd 1s Tsk 2s Contact service AKI not available Cause AKI not available Solution Connect AKI and activate Warning The plug for the option board can be inserted incorrectly in spite of the coding Check the plug Is the correct HAL file loaded AKI sensor error Contact service Cutter database is corrupt The data has been lost The standard values were used Contact service Automatic initialisation is not possible with this tool Cause The automatic initialisation tool cannot be used on this tool 000012 11 11 2009 jmu 6 23 Malfunctions G3 Series Error messages 0x0001C303 0x0001C403 0x0001C502 0x0001C602 0x0001C704 0x0001C803 0x0001C903 0x0001CA04 Solution This setting can be adjusted by the user However the default setting is supplied by the tool Maximum position reached Cause The travel range for the initialisation of the tool has been reached No tool in the module e Sensor defective AKI unexpected status Contact service The 2s command is only permitted in the service user level
11. Cleaning and maintenance G3 Series Maintenance jobs 1 Assembly base 5 Masking tape layer 1 2 Adhesive tape 6 Masking tape layer 2 3 Conveyor belt 7 Applicator gun with 2 component glue 4 Stapler 8 Spatula Setup the conveyor belt straight and fix in place with adhesive tape If necessary turn on the vacuum to prevent the conveyor belt slipping Push the assembly base under the fixed conveyor belt A Align the other end of the conveyor belt parallel to the fixed edge with a gap of approx 0 5 mm Fix in place with adhesive tape B Fix the aligned conveyor belt to the assembly base using the stapler and 6 mm staples C Place two offset layers of adhesive tape on both sides of the connecting gap D Before gluing apply a stripe of the glue from the applicator gun to a piece of paper This ensures that the glue which is emitted is correctly mixed Use the applicator gun to apply the 2 component glue to the connecting gap Ensure that the gap is completely filled with glue E As soon as the glue has been applied use a spatula to spread out remove the excess glue The glue needs around 5 minutes to bond F Apply the glue more liberally to the left and right edges to prevent tearing F The glue will be dry after approx 4 hours Remove all staples the adhesive tape and the assembly base 1 Fig 7 22 Reinforcing the edges Reinforce the left and right edges using gaffer tape Fig 7 22 item 1 to prevent
12. Modules are independently recognised by the cutter control unit Tools on the other hand do not have automatic recognition and must be manually allocated to a module Tool specific parameters initialisation moving speeds acceleration are saved to the corresponding tool and can be called up again at any time KCT 1 POT 1 EOT 1 EOT 2 Fig 4 15 Tool handling 4 24 000010 09 11 2009 jmu G3 Series Controls and operation Operation Marking the tools e g Fig 4 16 Marking the tool e g Label all tools of the same type with a consecutive number Appropriate adhesive labels are supplied with the equipment Create new tool Insert the marked tool in the required module Choose Select toof 1 1 1 in the menu gt Select NEW User request 5 Create new Item 1 Tool ty pe Mo tool 2 Tool number gt The popup menu Create new entry opens Select 7oo type 000010 09 11 2009 jmu 4 25 Controls and operation G3 Series Operation Tool type E Ao tool o UDT o UCT ocTT1 nl O Def Ok Esc gt All tool types that can be used in the current module are displayed in the popup menu 7oo type Select the tool from this list and confirm using OK Tool number 1 ka CLs Def Ok Esc gt Enter the appropriate number of the tool in the popup menu 700 number and confirm using OK Select t
13. 1 1000 mm s Down X amp Y speed Moving speed when the tool is lowered Adjusting value 1 1000 mm s Normal X amp Y accel Acceleration without activated SHIFT key Setting in m s Fast X amp Y accel Acceleration with activated SHIFT key Setting in m s Active tool 5 20 000015 040 11 2009 jmu G3 Series Description of menu 1 5 7 1 5 7 1 1 5 7 2 1 5 7 3 1 5 7 4 1 5 7 5 1 5 7 6 1 5 7 7 Description of menu Link to the active tool Module change pos Setting the position used when changing modules See chapter Controls and operation Inserting replacing the module Position Selecting the position used when changing modules Position 1 The module change is carried out at the point defined as Position 1 Position 2 The module change is carried out at the point defined as Position 2 Position 1 or 2 After entering 1 5 1 Change module the module change can be set for position 1 or 2 Position 1 Move to the position at which the module change should be carried out move and confirm with OK The position is saved as position 1 Position 1 X Display input the X coordinates of position 1 Position 1 Y Display input the Y coordinates of position 1 Position 2 Move to the position at which the module change should be carried out move and confirm with OK Position 2 X Display input the X coordinates of position 2 Position 2 Y Display input the Y c
14. 3 20 000011 08 11 2009 jmu G3 Series Safety 3 17 3 18 Risks arising from the emission of toxic dust Risks arising from the emission of toxic dust Warning Risk of poisoning from the emission of toxic dust Processing the most wide ranging materials can lead to the creation of toxic dust with significant risk to health e Obtain information about the toxicity of the material to be processed from the ma nufacturer e Use a suitable extraction unit or take other appropriate action accordingly The company operating the system is responsible for making sure that all national regulations concerning the maximum permissible dust concentration at work are adhered to When handling hazardous types of dust all local safety regulations as well as the manufacturer s instructions must be observed Use special vacuum cleaners with specially adjusted dust filters if you are routing processing hazardous materials Z nd offers suction systems which meet the following regulations as accessories The extraction of hazardous dusts with a maximum concentration at work of up to 0 1 mg m and the extraction of wood dusts of dust class M The extraction of dusts conforming to dust class H Risks arising from the processing of toxic hazardous materials Warning Risk of poisoning from emissions when processing toxic materials Processing the most wide ranging materials can lead to toxic emissions gases dust etc with s
15. G3 Series 000017 03 06 2009 jmu 7 7 11 Draining the maintenance unit condensation water 24 7 7 12 Automatic circuit breakers 0 0 eee 25 TEENS Conveyor Delt 5 200 Bhad AAA a dee nh ate DNR 27 7 7 13 1 Removing the conveyor belt 0 0 tee 27 7 7 13 2REMOVING thE COVELS ooo 28 7 7 13 3Fitting a conveyor Delt te 29 7 8 Instructions for disposal 000 00 e eee eee eee eee 36 7 9 Starting up after periods ata standstill 36 7 9 1 Vacuum generator 1 9 KW 1 15 KW 1 naana 36 8 MOONS 355 anien esa re Bae Geek hate eee adh aoe aed tee 1 9 Modules 23 4 aens eye eee tee a eee 1 10 Options 3 202i 3645 2 A bie Cai ees 1 11 Material handling 2 0 cece te eee 1 12 Additional specifications 0c ccc ee een eee 1 13 Documents ii wi sn we Agee eee beat eae Pee 1 14 GlOSSANY suizo pe iP entice A A aoe keke ence BREE A eee 1 0 5 G3 Series 000017 03 06 2009 jmu G3 Series Introduction Foreword 1 Introduction Z nd Systemtechnik AG Altst tten Switzerland 1 1 Foreword Dear customer By purchasing our product you are participating in the worldwide success of Z nd cutter systems The modular design of our systems ensures e A system solution that is suited to your individual requirements in terms of speed and quality The availability of the most up to date technology thanks to constant develop ments Our appro
16. G3 Series Controls and operation Module and tool holder 4 13 Module and tool holder Attention Always store any unused tools and modules correctly in order to avoid any damage to them Store any unused modules and tools in the module and tool holder The module and tool holder has space for two tools and two modules Fig 4 39 Module and tool holder 4 53 000010 09 11 2009 jmu Controls and operation G3 Series Switch off the machine 4 14 Switch off the machine To switch off the machine proceed as follows gt Switch the cutter into the operating status OFFLINE gt Select the function Shut down cutteri2 from the menu or press the key combination SHIFT Y O Shut down cutter ti Shut down cutter now IE E Use Yes to confirm gt The start page appears on the display gt Switch off the machine using the main switch If necessary secure the main switch using a lock to protect the machine against incorrect commissioning gt Clean the machine to remove dust and material residues 4 54 000010 09 11 2009 jmu G3 Series Description of menu General 5 Description of menu Valid from firmware 1 43 5 1 General The menu description contains all menu entries and commands However entries which repeat periodically module 1 module 4 are only listed once Explanations on module tool specific menu entries can be found in the operating manual of the respective mo
17. HAL Bit has already been assigned HAL file row number 0s Contact service HAL IO hardware element not loaded HAL file row number 0s Contact service HAL No hardware has been assigned to the virtual object Contact service Data initialisation error Contact service HAL Error when reading the HAL function HAL file row number 0s Contact service HAL Error when reading the HAL function parameter HAL file row number 0s Contact service HAL Error when reading the hardware ID HAL file row number 0s Contact service HAL Err reading 8 bit value HAL file row number 0s Contact service HAL Error when reading a frequency value HAL file row number 0s Contact service HAL Error when reading a value HAL file row number 0s Contact service 000012 11 11 2009 jmu 6 5 Malfunctions G3 Series Error messages 0x00008C02 0x00008D02 0x00008E03 0x00009B03 0x0000A402 0x0000A603 0x0000A703 0x0000A902 HAL Error when reading a Boolean value HAL file row number 0s Contact service HAL Unknown HAL element found HAL file row number 0s Contact service HAL An HW element could not be connected with an MUX HAL file row number 0s Contact service The selected module is not supported Cause At the moment the selected tool module is still not supported For example an attempt was made to change to module 4 even though module 4 is not ava
18. Push bar away from the cover that is to be removed gt Remove the screws gt Remove the covers 7 13 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs Cleaning the guide rails Fig 7 5 Oiling the guide rails gt gt Push the bar forwards Thoroughly clean the entire length of the guide rails using a lint free rag Soak a lint free rag with lubricant for guide rails bearings and oil the guide rails Fit the covers 7 14 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs 7 7 6 Oil X axis guide bearings Tools and materials Lubricant for guide rails bearings Greasing set for X axis guide rails bearings X 4mm Allen key Clean lint free rags Ensure that following precondition is fulfilled 1 The machine is in the maintenance position Remove the covers Fig 7 6 Remove the covers gt Push the bar backwards gt Remove screws Remove the covers 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs Guide bearings Fig 7 7 Guide bearings The bar is mounted with 2 guide bearings on a guide rail on each side Oil these bearings at intervals according to the maint
19. gb014_2 gt Regain operational safety gt Turn the emergency stop switch clockwise until it is unlocked gt Use F7to reinitialise the machine Function test Danger Risk of injury due to defective emergency stop switches Machines with defective emergency stop switches are not safe for operation In hazardous situations the machines cannot be stopped promptly e Check that the emergency stop switches are working on a daily basis Do not start up a machine with defective emergency stop switches until the pro blem has been remedied by authorised personnel gt Press all emergency stop switches before the start of work after the initialisation of the device v Ifthe machine stops correctly then it is safe for operation Problem solution The machine does not stop correctly following the activation of an emergency stop switch gt Do not start up the machine Let authorised personnel remedy the problem 4 8 000010 09 11 2009 jmu G3 Series Controls and operation Controls 4 3 3 Maintenance unit The maintenance unit adjusts the air pressure to the switching of the vacuum elements various modules and options CS gt 5 Fig 4 9 Maintenance unit 1 Stopcock 4 Air pressure setting for conveyor clamp 2 Water separator elements and feed elements P3 5 Fixing bracket for an additional optional maintenance unit for various modules tool inserts and optio
20. the conveyor belt from tearing 7 34 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs Tensioning the conveyor belt Fig 7 23 Tensioning the conveyor belt 1 Left right tensioning screws Tighten tensioning screws The conveyor belt is tensioned Repeat the procedure on the other side Aligning the conveyor belt run Inthe menu set the conveyor belt run to 10 m Length 7 7 1 3 gt Start an automatic belt feed Start 7 7 7 7 Adjust the conveyor belt run using the tensioning screws if necessary 7 35 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Instructions for disposal 7 8 7 9 7 9 1 Instructions for disposal Important Contact Z nd customer services or your service partner before you dispose of your cutter Z nd cutters are modern industrial devices which correspond with the current standards and guidelines on the disposal of old appliances e Plastic components gt 20 grams are labelled and can therefore be disposed of correctly Steel and plate parts have been varnished with environmentally friendly varnish or have been powder coated Aluminium components have been anodised They can be disposed of as waste metal PCBs have been soldered with lead free solder and be disposed of as electric waste You must also observe the following e Country specific legislation and regulations on waste disposal No
21. 0 Transport to the back Important A transport to the back can only be executed when the feed system is correspondingly configured 000015 040 11 2009 jmu 5 25 Description of menu G3 Series Description of menu 1 7 2 3 1 7 11 6 1 7 3 1 7 3 1 1 7 3 2 1 7 3 2 1 7 4 1 7 4 1 1 7 4 2 1 7 4 2 1 7 6 1 7 6 1 1 7 7 1 7 9 1 7 9 1 1 7 9 2 A feed is executed Starting point current position End point X max Lower feed clamps Feeding clamps are lowered to fix the material Lift feeding clamps Raise feed elements Driven unwind options Settings of the unwind unit with core uptake Unwinding unit core Activate deactivate unwinding unit with core uptake Unwinding unit on Switch on unwinding unit Unwinding unit off Switch off unwinding unit Driven wind up options Settings of the wind up unit with core uptake Wind up unit core Activate deactivate wind up unit with core uptake Wind up unit on Switch on wind up unit Wind up unit off Switch off wind up unit Ext material handling 1 Settings for external material handling 1 Ext mat handling Switch external material handling off on Ext material handling 2 Settings for external material handling 2 Unwind options Set universal unwinding unit Unwind options Switch universal unwinding unit on off On Universal unwinding unit is active Off Universal unwinding unit is not active Status 5 26 000
22. 1 MC Description to follow 8 5 2 Operating unit 8 5 3 MC version Display of the master controller version 8 5 4 MC Build Internal number 8 5 6 Oper unit build Internal number 8 5 7 YM board Software version of the Y board 8 5 8 Camera board Description to follow 8 5 9 Mod board 1 Description to follow 8 5 10 Mod board 2 Description to follow 8 5 11 Mod board 3 Description to follow 8 5 12 Mod board 4 Description to follow 8 6 Actual e box temp 5 44 000015 040 11 2009 jmu G3 Series Description of menu Description of menu Display of the current E box temperature 8 7 Max E box temp Maximum permitted E box temperature 8 9 X mot temp Display of the temperature of the X drive motor 8 10 Actual system outputs Current system outputs 8 10 1 Output curve Output curve 8 10 2 Output IPC buffer Output IPC buffer 8 10 3 Output Log buffer Output Log buffer 8 11 Stored system output Stored system outputs 8 12 Operation hours The operating hours counters are used to determine various maintenance activities See chapter Maintenance cleaning Maintenance schedule 8 12 1 Cutter Display of the cutter s operating hours 8 12 2 Vacuum turbine Display of the vacuum turbine s operating hours 12 Shut down cutter Switch off the machine 000015 040 11 2009 jmu 5 45 Description of menu G3 Series Description of menu 5 46 000015 040 11 2009 jmu G3 Series Malfunctions 6 1 6 2 Troub
23. CIO eiii ia a leh the Sad deed AE eon etn Bee yd 1 6 21 Error display sas A Sad Un A ee 2 02 27 ENON COG n la li 3 6 3 ErrOrMe SSaGeS ceo ened pete el ea eee eo eed eed 4 7 Cleaning and maintenance 00 00 cee eee eee 1 7 1 CN ha re e e e la te peta Ah Sa 1 7 2 Safe maintenance of the machine o oooccccccoooocooo eee 2 7 3 Operating reSOUrCeS 2 oe eee eee 3 7 3 1 Handling operating materials auauua aaau 3 1 32 Cleaning Mids eve bands deen dd ate de died dee RA 4 TSS JEUDNCAMS a dl idea 4 TIA VAdNeSIVES ri A hee dea oe ad 4 7 4 Steps for maintenance 0 000 eee eee 5 7 5 Lubrication diagram sosti ea a teas 8 7 6 Accessories CASE bois Soke nial Leda held ee uae eld Ghats 8 7 7 Maintenance jobs 2 ke ee ee ee a OS 10 7 7 1 Service flaps and covers 0 00 cece eee eee eee 10 7 7 2 Maintenance position 00 0000 e eee eee 11 7 7 3 Visually inspect the machine for damage 0 2e eee eae 11 7 7 4 Clean the machine 02 00 ccs 12 7 7 5 Clean X axis guide rails 2 1 0 0 eee 13 7 7 6 Oil X axis guide bearings ooooccococcccor eee 15 7 7 7 Cleaning oiling Y axis guide rails 0 eee ee 19 7 7 8 Lubricating the Y axis bearing 0 0 eee 21 7 7 9 Clean the chipping protection brush 2000000 0 eee 22 7 7 10 Cleaning the feeding clamps feed guide rail 23 000017 03 06 2009 jmu
24. Contact service This type of AKI position indicator is not supported Contact service Parameter transfer complete Restart the cutter in order to use the new parameters AKI in the park station Cause The AKI must not be in the park station during use An attempt was made to carry out tool initialisation even though the AKI is still in the park station Solution Position AKI on the table AKI not in the park station Cause The action to be carried out e g start up demands that the AKI is in the park station Solution Position AKI in the park station Restart cutter Errors occurred during the parameter transmission Nothing has been saved Restart the cutter in order to restore the old status Contact service 6 24 000012 11 11 2009 jmu G3 Series Malfunctions 0x0001CB02 0x0001CD03 0x0001CE03 0x0001CF03 0x0001D003 0x0001D204 0x0001D303 0x0001D402 Error messages Automatic initialisation tool blocked for tool Cause The initialisation of the tool is blocked via the automatic initialisation tool Solution Change the corresponding tool parameter AKI_possible Unexpected programming error Contact service Invalid controller parameter Contact service Error in the message parameter Cmd 0s Task 1s Contact service Incorrect axis sequence Contact service The power unit is too hot The electronics may be damaged Cause The power unit is too hot the c
25. Enter the first byte 5 3 5 2 Byte 2 Enter the second byte 5 3 5 3 Byte 3 Enter the third byte 5 3 5 4 Byte 4 Enter the fourth byte 5 3 6 Set IP template Entry of the network template 5 3 Logger software for reading the log data 5 3 1 Log output Switch log output of the communication settings on off 5 5 Interface Selection of interface used for data transfer COM1 Data transfer via serial interface COM1 Ethernet Data transfer via ethernet interface 5 41 000015 040 11 2009 jmu Description of menu G3 Series Description of menu 6 Operating unit Settings for the operating unit 6 1 Language You can set your user language in this submenu Select the required language Choose OK to confirm 6 2 Volume Setting of the signal volume gt Enter value for the volume gt Use Save panel settings 6 8 to save the settings 6 3 Panel contrast Setting of the contrast of the display gt Enter value for the contrast gt Use Save panel settings 6 8 to save the settings 6 4 Length unit Setting of the measurement unit US units Si units Select the required unit Choose OK to confirm gt Use Save panel settings 6 8 to save the settings 6 5 Function keys Definition of the function keys see chapter Controls and operation Function keys 6 6 Date format Setting the date format gt Select date format gt Use Save panel settings 6 8 to save the settings 6 7 Date and time Setting the date and the time 6 8 S
26. HAL Not possible to configure the lO HAL file row number 0s Contact service HAL An output port has been defined for this HAL element Contact service HAL Not possible to set the IO direction HAL file row number 0s Contact service HAL An input port has been defined for this HAL element Contact service Module selection error Contact service No reference to the module carriage Contact service Insufficient parameters Contact service Module not available Cause The currently installed tool head cannot be accessed on the required module Solution Select the correct module or change the tool Z axis init error Axis 0s Status 1s Contact Service 6 12 000012 11 11 2009 jmu G3 Series Malfunctions 0x00014203 0x00014403 0x00014501 0x00014B03 0x00014C03 0x00014D02 0x00014E02 0x00014F03 0x00015003 0x00015102 Error messages T axis init error Status 1s Contact Service Incorrect module active Select the module 0s Contact service Operating status in the process of changing Contact service Incorrect sequencer status Contact service Peripheral could not be entered into the list Contact service Peripheral could not be found in the peripheral list Contact service Incorrect tool type Cause This tool type is not supported Solution Select available tool Tool connection not available Cause An attempt was made
27. Menu navigation 4 4 5 User level Access to menus and functions is blocked according to the user level The user levels have a hierarchical structure This means that the next highest user also has the access rights to the menu functions that the subordinate user has User level Description Users 1 3 All menus and functions that are needed for the operation of the machine are accessible Operator Simple uncomplicated settings work is permitted Service Cutter settings that can only be carried out by authorised service personnel Factory setup Change user levels gt Change to the menu Password4 2 gt Enter your user code Y The user level is approved and is displayed under User4 1 Problem solution The system does not change to the required user level gt Check the user code for your user level and repeat the entry Defining active user level after start up Important After start up it is not possible to define a user level that is higher than your own as an active user level gt Change to the menu Start user4 3 gt Select the desired user Y The selected user level will be active the next time the cutter is started Changing the passwords for user levels 2 and 3 Important The passwords for user levels 2 and 3 can be changed in the Operator user level or higher gt Change to the menu Change password4 4 gt Select user gt Enter the new password for tha
28. cece dake ic pe al a ene alee 41 481 Feeding clamps i ee devs ies cee cae eee ene Ca Sie bh Ae 42 4 8 2 Feed guide rall dico ceca ea a A RE eee ee S 43 0 3 G3 Series 483 Feeding optionS Witt da ee ee Sh 44 4 8 3 1 Automatic feed 1 0 44 4 6 3 2 Manual feed uti Deda wallet aban lhe peels ae ee dae aed 44 4 9 Automatic tool initialisation AKI 0 0 00 e ee eee 45 49 1 Description 2 2 00 bee eed a bev bebe a Pe eee ee 45 4 9 2 Adjustingthe height 0 cee eee 46 4 9 3 Initialisation ooooooocoooooooooor eee 47 4 10 Laser pointer reference point 02000 cee eee eens 48 4 10 1 Laser pointer settings 0 0 0 cee eee 48 4 10 2 Reference point settings 0 0 eee eee 49 4 10 3 Choose laser pointer as pointer type 000000 eee eee 50 4 10 4 Define reference point 00000 eee 50 4 11 Material st p since dite doin a he mae Rane war gions 51 4 12 Module carriage slot protective plate o ooooooocoooo 52 4 13 Module and tool holder 0 02020 eee 53 4 14 Switch off the machine 22 20 eee 54 5 Description of menu 1 eens 1 5 1 Generals 84 0 Sa ede the talon aaah alte 2 ee Re eee ee 1 5 2 Menu structtires 22 lt 4 0c tae toda a Rae ee ales rA da 1 5 3 Description of Menu ooo 2 6 Malfunctions ee oli heed o Di da 1 6 1 TroubleshootiNg accede bok eG eke a Monee ae 1 6 2 Locate
29. health if handled carelessly Always wear personal protective equipment when working with chemicals Explanation of the hazard label Hazard label for toxic substances Hazard label for harmful substances Hazard label for irritating substances Important Chemicals classed as irritants are used to operate and clean this machine cleaning agents operating fluids Safety datasheets of the substances in question can be downloaded from the Z nd homepage www Zund com Safe handling of chemicals Disposal Dispose of chemicals in accordance with national regulations e Store chemicals in tightly closed containers in a cool dry place between 5 C and 30 C e Protect the containers from heat and direct sunlight e Provide good ventilation including at floor level Store chemicals in accordance with local regulations e Keep containers tightly closed e Use chemicals only for the intended purpose 000011 08 11 2009 jmu 3 23 Safety G3 Series Risk of fire and explosion 3 21 Risk of fire and explosion Warning There is a risk of fire when routing and cutting inflammable materials Terminate the routing cutting and leave the tool to cool in the case of e Formation of smoke e Discolourations on the router knife which point to increased heat development Warning Risk of dust explosions Flying sparks or electrostatic charges result in the risk that there will be dust explosions duri
30. individual connection which must be assigned via the cutter control unit before the initial commissioning of the respective tool There are 3 electrical connections ports available on the distributor of the laser pointer ICC camera Pneumatic tools can be assigned to other ports Connection pneumatic tools Tool Connection port POT Port 4 Procedure gt The tool is attached and allocated to the module gt Use 7oo connecton 1 1 3 1 1 to allocate the tool connection to the corresponding port Y The tool is ready for use 4 32 000010 09 11 2009 jmu G3 Series Controls and operation 4 6 7 1 Connection electrical tools EOT DRT etc NA JA gb169 Fig 4 22 Connection electrical tools 1 Connection 1 port 1 2 Connection 2 port 2 3 Connection 3 port 3 Procedure gt gt The tool is attached and allocated to the module Insert the tool into the connection provided Use Too connector 1 1 3 1 1 to allocate the tool connection to the corresponding port The tool is ready for use Operation 000010 09 11 2009 jmu 4 33 Controls and operation G3 Series Operation 4 6 7 2 Connect pneumatically driven tools Pneumatically driven tools and modules are connected to the interface unit on the module carriage The pressure is set using a maintenance unit The air supply is connected to the local installation or supplied vi
31. jmu G3 Series Malfunctions 0x0000F 203 0x0000F 304 0x0000F403 0x0000F502 Ox0000FA01 Ox0000FB01 0x0000FC01 Error messages Safety module gave notification of error Has an emergency stop key been pressed Mode 0s Cause Error in basic function change emergency stop 0x01 gt No emergency stop active 0x02 gt 24V_NA still available 0x04 gt Emergency stop still active 0x08 gt Emergency stop not active 0x10 gt Safe_Con incorrect 0x20 gt A1_EMM incorrect Solution Check emergency module or basic function board Incorrect voltages on the BASIC FUNCTION BOARD Contact service HAL Unknown internal lO port HAL file row number 0s Contact service HAL No interrupt signal was assigned to an active port bit Contact service Editor open on other op unit Shut the editors on all other operating units and try again Cause Parameters are currently being edited on another operating unit While this is happening no data can be edited on a second operating unit Solution Wait until the editor is closed on the other operating unit Attempt another time This user level requires a password Cause If the user level has been changed and a password is needed for this purpose then the entry of the password is displayed with this message Access denied Incorrect user code 000012 11 11 2009 jmu 6 9 Malfunctions G3 Series Error messages 0x0000FE04 Ox0000
32. longer be moved Solution The initial status can be reproduced by carrying out a reinitialisation of the head When confirming the error the head is reinitialised to module 1 Error when exporting the user log file Contact service 000012 11 11 2009 jmu Malfunctions G3 Series Error messages 0x00018402 0x00018504 0x00018602 0x00018701 0x00018803 0x00018A03 0x00018B03 0x00018C02 0x00018D03 0x00018E03 Value is not a valid number Contact service Timeout during start up No communication to the system Contact service Error when setting the axis position Contact service Please wait Cause The user must wait until the function has terminated Error with the database trigger Contact service Internal error No owner task Contact service Error during access to the edge sensor Contact service Reference point outside of the limits Cause The reference point was set outside of the travel range Solution Authorise or move reference point Tool overcurrent Cause An overcurrent error occurred in the tool Solution Pull the tool out of the material Excess module temperature 6 18 000012 11 11 2009 jmu G3 Series Malfunctions 0x00019003 0x00019103 0x00019302 0x00019402 0x00019503 0x00019702 0x00019801 0x00019904 0x00019A01 Error messages Cause The module is too hot Solution Wait until the module has co
33. maintenance personnel S e e One off activity O One off activity bess z E Repetitive interval O Repetitive interval a gt S 3 If necessary If necessary 3 Ass 26 5 O Check alignment of toothed steel belt and readjust if necessary O Check tension of toothed steel belt and readjust if necessary O Check the belt tension yk Replace V belt O Clean and lubricate the gears Module carriage O x Check clearance replace bearing if necessary E O Lubricate bearing 7 7 8 O Replace wiper Vacuum generator 1 9 KW 1 15 KW O Check correct functioning O Clean filter O Conveyor Check piping for damage and tightness replacement O 6000B General inspection Compressor E Check the oil level if necessary top up oil according to specifications E E Check water separator and drain water if necessary S E Drain condensate from air cylinder gt a Check pressurised pipes for leaks eliminate any faults E Check air intake filter replace if clogged 3 E Clean compressor 2 a Check piping for damage and tightness E O Check the function of the safety valve adjust if necessary O Replace compressor oil S 2 ka ra Maintenance unit E O Drain condensation water 7 7 11 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Lubrication diagram 7 5 Lubrication diagram Lubricate all lubricating points indicated in the lubrication diagram in accordance with the specified maintenance intervals The machine is lubricated usin
34. moves to the zero position The ONLINE operating status is activated Exit park Move to park position The module carriage moves to the defined park position Park position mode Definition of which park position is to be moved to The following modes are available Axis Description X axis The module carriage moves to park position X Y axis The module carriage moves to park position Y X Y axis The module carriage moves to park position X Y 5 22 000015 040 11 2009 jmu G3 Series Description of menu Description of menu 1 6 1 4 X park pos Definition of the X coordinates of the park position 1 6 1 5 Y park pos Definition of the Y coordinates of the park position 1 6 2 Light barrier options Warning 1 6 2 5 1 1 6 2 5 2 Risk of injury caused by non activation of safety devices The light barriers are part of the safety device e only deactivate the light barriers for installation purposes at Z nd e before delivery activate the light barriers and check that they function Fig 5 15 Light barrier options 1 Front light barrier 3 Reflex light barrier 2 Back light barrier Menu for activating deactivating the light barriers Front light barrier Testing the front light barrier Error Light barrier defective Free The light barrier is not interrupted Interrupted The light barrier is interrupted Back light barrier Testing the front light barrier Err
35. out in the ONLINE operating status and a travel key is pressed then the operating status changes to OFFLINE 4 3 1 6 Soft keys Select tool O Neo tool 0 a UDT 1 o UDT 2 o UCT 11 Lew Delete Ok Esc TT Fig 4 7 Soft keys These keys change their function depending on the situation The currently valid function is shown in the display 4 5 000010 09 11 2009 jmu Controls and operation Controls 4 3 1 7 Special keys shortcuts G3 Series Important functions are defined with separate keys on the operating unit Current Function operating status With SHIFT key Without SHIFT key STOPPED Switch off the machine Change to OFFLINE ONLINE Switch off the machine E ange to OFFLINE Switch off the machine 9 Current Function operating status With SHIFT key Without SHIFT key Vacuum off Switch vacuum on te Vacuum on suction Vacuum menu Switch vacuum off Vacuum on blowing Current Function position With SHIFT key Without SHIFT key Up Z pos e Lower tool into lower position os Lift tool into park position l y Down Z pos Raise tool into upper position Park position Lower tool into upper position Current Function operating status ONLINE e OFFLINE See section 4 6 3 STOPPED 4 6 000010 09 11 2009 jmu G3 Series Controls and operation 4 3 2 Controls Emergency stop sw
36. point starting point corresponds to the zero point in the coordinate system of the job file See chapter Controls and operation Laser pointer reference point Pointer type 000015 040 11 2009 jmu Description of menu G3 Series Description of menu 1 5 2 2 3 5 1 3 5 1 3 5 3 1 5 2 2 4 1 5 2 2 5 1 5 2 2 6 1 5 3 1 5 3 1 1 5 3 2 1 5 3 3 1 5 3 4 1 5 4 Both the current tool and the laser pointer can optionally be defined as the pointer for defining the reference point Select the pointer or tool and confirm with OK Y The setting is saved Camera Camera installation settings Lighting off Switch camera lighting off Lighting on Switch camera lighting on Lighting strength Setting of the camera lighting strength The strength can be adjusted in seven levels Shutter speed Setting of the shutter speed AUTO is usually used to automatically determine the optimum shutter speed White balance Setting of the white balance AUTO is usually used to automatically determine the optimum white balance If an optimum value cannot be achieved using AUTO you can manually adjust the white balance to the light source in question BLC Switch on the backlight correction See ICC camera Manual move settings Setting of the speed and acceleration for the procedure using the travel keys on the operating unit Up X amp Y speed Moving speed when the tool is raised Adjusting value
37. pointer reference point 4 10 Laser pointer reference point Attention Laser class 2 Looking directly into laser beam will damage the eyes Avoid looking directly into the laser beam The laser pointer is an optical instrument for visually determining the reference point It is attached to the module 4 10 1 Laser pointer settings Fig 4 34 Laser pointer settings 1 Connection 1 port 1 3 Connection 3 port 3 2 Connection 2 port 2 4 Laser beam exit 4 48 000010 09 11 2009 jmu G3 Series Controls and operation Laser pointer reference point 4 10 2 Reference point settings A reference point can be defined on the working area of the cutter This reference point is the starting point for the processing procedure and corresponds to the zero point of the processing file Fig 4 35 Reference point settings 1 Working area zero point 3 Processing file zero point 2 Reference point settings 4 Processing pattern 4 49 000010 09 11 2009 jmu Controls and operation G3 Series Laser pointer reference point 4 10 3 Choose laser pointer as pointer type Both the current tool and the laser pointer can optionally be defined as the pointer for defining the reference point gt Select the function Pointer type1 5 2 1 1 Select the laser pointer Y The laser pointer has been selected and saved as the pointer 4 10 4 Define reference point Example Active tool EOT position 7oo 2 1
38. special measures are generally required when decommissioning the cutter system because no poisonous substances are used e Assign a disposal company to remove and recycle the machine correctly Starting up after periods at a standstill Important Before extended periods of downtime for commissioning of your cutter after periods at a standstill contact the Z nd Customer Service department or your service partner In general the machine can be started up immediately even after prolonged periods at a standstill Some options however require running in routines which must be respected in order to ensure further maintenance free operation Vacuum generator 1 9 KW 1 15 KW Running in routine after periods at a standstill gt 6 days Activate all vacuum zones gt Run in the vacuum unit for approx 4 minutes at level 1 gt followed by approx 4 minutes at level 2 Y The vacuum generator is ready for operation 7 36 000001 10 11 2009 jmu G3 Series Tools 8 Tools 8 1 000005 04 06 2009 jmu Tools G3 Series 000005 04 06 2009 jmu G3 Series Modules 9 Modules 9 1 000004 04 06 2009 jmu Modules G3 Series 000004 04 06 2009 jmu 10 G3 Series Options 10 Options 000007 04 06 2009 jmu 10 Options G3 Series 10 2 000007 04 06 2009 jmu 11 G3 Series Material handling 11 Material handling 000006 04 06 2009 jmu 11 Material handling
39. the front and rear side of the beam Important The light barriers are active in all operating states Operating unit Malfunctions are indicated on the LCD display An acoustic signal is emitted in the case of emergency stop and to acknowledge keypad entries 000011 08 11 2009 jmu Safety G3 Series Safety and monitoring devices 3 12 3 Emergency stop switch Emergency stop switches are part of a protective circuit They allow the machine to be turned off quickly in hazardous situations Two emergency stop switches can optionally be fitted on the edges of the machine The mains power supply to the whole machine is switched off as soon as the emergency stop switch is pressed The operating unit remains switched on Attention Pressing the emergency stop switch can damage the cutter Do not press the emergency stop switch to switch off the machine in routine operation Important To unlock an activated emergency stop switch after regaining operational safety turn the switch anticlockwise see chapter Controls and operation 3 12 4 Safety cut off feature The following safety measures are introduced when an overload occurs or an axle drive T X Y Z is blocked An emergency stop is carried out The cutter switches to the operating status STOPPED An error message and an alert buzzer indicate the safety cut off 3 16 000011 08 11 2009 jmu G3 Series Safety Personal protective
40. to link a tool to a connection that is not available Solution Select another port Tool timeout already active Contact service No timeout job active Contact service 000012 11 11 2009 jmu 6 13 Malfunctions G3 Series Error messages 0x00015201 0x00015304 0x00015401 0x00015502 0x00015604 0x00015702 0x00015802 0x00015901 Database successfully saved Contact service Whole DB deleted The cutter must be restarted Contact service System is in the operating status STOPPED Cause The system status may not be changed because the system is in the operating status STOPPED It is only possible to leave the operating status STOPPED using operating unit 1 Solution Change operating status via operating unit 1 Incorrect parameter for the arc command Cause An attempt was made to draw a circle The transferred parameters do not correspond with the definition This error is transmitted if the data length of the message is incorrect Solution Correct the parameters Module tool voltage error Index 0s Contact service HP GL response function not found Contact service Incorrect parameter Cause Incorrect parameters were transferred when switching the tangential rotation on or off Solution Correct the parameters The entire database was successfully reset to the default values 6 14 000012 11 11 2009 jmu G3 Series Malfunctions 0x00015
41. trained personnel G 3 12 000011 08 11 2009 jmu G3 Series Safety Safety signs Laser radiation Do not stare into Laser beam warning beam Laser class II 000011 08 11 2009 jmu Safety G3 Series Safety and monitoring devices 3 12 Safety and monitoring devices Fig 3 6 Safety and monitoring devices 1 Emergency stop switch 3 Operating unit 2 Protective system 000011 08 11 2009 jmu G3 Series Safety 3 12 1 3 12 2 Safety and monitoring devices Protective system Attention If there is a collision the bar may cause serious injuries The high level of kinetic energy of the drive results in a braking distance which cannot be ignored Light barriers and safety cut offs are no guarantee against injuries The protective system is made up of protective trip switches and light barriers on the ends of the bar Protective trip switches and light barriers are part of a self monitoring safety shutdown system If protective trip switches or light barriers cause an obstruction then the following protective measures are introduced An emergency stop halts all movements The operating status STOPPED is activated An error message is displayed Protective trip switches Protective trip switches trigger the safety shut down if they are touched by an obstruction They are used as hand protection Light barriers The working area is monitored by light barriers on
42. until the temperature reduces No sealing air available Cause Sealing air is not no longer available Solution Check sealing air Machine not implemented Contact service Settings are saved The blower has already been in use for more than 6000 h Please contact the service department Cause The vacuum generator has already been in use for more than 6000 h Solution Contact your service partner The blower has already been in use for more than 8000 h Only half the power can still be used Cause The vacuum generator has already been in use for more than 8000 h Only a maximum of half the power is still available Solution Contact your service partner 6 28 000012 11 11 2009 jmu G3 Series Malfunctions 0x0001F603 0x0001F703 0x0001F803 0x0001FA03 0x0001FB03 0x0001FC01 0x0001FD04 0x0001FE02 0x00020002 0x00020102 0x00020204 Error messages Callback functions could not be registered Contact service The speed requirement could not be reached Cause The speed requirement of the router was not reached Altera ZERO pointer Contact service Error when writing data via Z link Index 0s Contact service Error when reading data via Z link Index 0s Contact service OptionBoard Str1A not available The manual feed table was therefore deactivated Contact service Timeout in the sequencer Error 0s Last cmd 1s Contact service Err in
43. was therefore deacti vated Contact Service OptionBoard Str1A not available The clamping bars were therefore deactivated Contact Service The desired feed direction has not been approved Too many measuring points Make area smaller or enlarge grid Measurements cannot be made with the selected module There is no valid data to repeat the measurement There is no measured area that can be displayed No valid data An area must be measured first The specified area is too small 000012 11 11 2009 jmu 6 35 Malfunctions G3 Series Error messages 0x00025C02 0x00025D02 0x00025E03 0x00026002 0x00026103 0x00026203 0x00026303 Axis inspection err Axis 0s Error 1s Contact Service The camera offset is outside of the permitted range Error in setting up TCPIP environment Index 0s Contact Service A connection request from a second computer via Ethernet has been rejected Error in module 0s Index 1s Contact Service The surface could not be detected This error message has been caused by the following The brushes of the UM provide too much resistance e The surface of the material to be processed is too soft The two readings of the SpeedReadyBit produced different results Index 0s Contact Service 6 36 000012 11 11 2009 jmu G3 Series Cleaning and maintenance General 7 Cleaning and maintenance 7 1 General This chapter describes
44. 0 000010 09 11 2009 jmu G3 Series Controls and operation Operation 4 6 3 1 OFFLINE Attention Risk of injury due to automatic starting of the machine In the OFFLINE operating status the cutter receives commands from the operating software These commands can be used to switch to the operating status ONLINE e Activate the operating status STOPPED during breaks Always carry out set up work in the operating status STOPPED ON A red flashing LED on the ONLINE key indicates that the operating status LINE OFFLINE is active When the machine is switched on the operating status OFFLINE is active In this status commands are received from outside but they are not processed Operating software commands can be used to switch to the operating status ONLINE 4 6 3 2 STOPPED Important The operating status STOPPED protects the operator from the machine being set into motion using remote controls ON A red illuminated LED on the ONLINE key indicates that the operating status LINE STOPPED is active In this operating status commands e g HPGL are received but they are not processed Even commands from the operating software e g to change to the ONLINE operating mode are ignored gt must be pressed in order to activate the operating status STOPPED The displays shows the following message Wo remote start possible Press for more into ESC to leave this dialog gt Use x to switch fro
45. 00003 06 11 2009 jmu G3 Series Product description Modules tools Router module for the use of 1000 W Z nd motor spindles Motor spindle with 1000 W for the processing of the most wide ranging materials Punching and stamping module for the processing of leather materials 2 7 000003 06 11 2009 jmu Product description G3 Series Material handling options 2 6 Material handling options 2 6 1 Laser pointer The laser pointer is used as an aid for the precise definition of the reference point b 158 2 6 2 ICC camera The ICC camera is used as an aid for importing the registration marks The processing of the data is dependent on the communication software 2 6 3 Cutter with static work surface gb 153 The feeding and removal of the processing material takes place on the work surface of the cutter The work surface is protected against damage using a cutting base Fig 2 6 Static work surface 2 8 000003 06 11 2009 jmu G3 Series Product description Material handling options 2 6 4 Cutter with conveyor a152 Conveyor systems are used for pulling the materials to be worked with The conveyor belt is used as a cutting base and conveyor belt at the same time During the processing the material to be processed is fixed in place using a vacuum After cutting the bar moves bac
46. 015 040 11 2009 jmu G3 Series Description of menu 1 7 9 3 1 7 9 4 1 7 11 1 7 11 2 1 7 11 3 1 7 12 1 7 12 1 1 7 12 2 1 7 12 2 1 7 18 1 7 18 1 1 7 18 2 1 7 18 2 1 7 18 3 1 1 7 18 3 2 1 7 19 1 7 19 1 Description of menu Display of status messages for servicing purposes Error Display of error codes for servicing purposes Comm error All feed system communication errors are counted statistics Feeding clamps Settings for the feeding clamps Release mode Switching countermovement on off Countermovement During the feed the bar moves the set path backwards in order to ensure that the feeding clamps can be raised Feeding bar Description to follow Feeding bar Description to follow Fix feeding bar Description to follow Release feeding bar Description to follow Manual feed table Functions for setting the manual feed table Manual feed table Activate deactivate the stop of the manual feed table Raise stop Raise the stop Lower stop Lower the stop Lift time Time in milliseconds until the stop is completely raised Lower time Time in milliseconds until the stop is completely lowered Fusion Feeder Description to follow Fusion Feeder 000015 040 11 2009 jmu 5 27 Description of menu G3 Series Description of menu 1 7 19 2 1 7 19 2 1 8 1 8 1 1 8 1 1 1 8 1 2 1 8 1 3 1 8 1 4 1 8 2 1 8 2 1 1 8
47. 09 11 2009 jmu 4 45 Controls and operation G3 Series Automatic tool initialisation AKI 4 9 2 Adjusting the height Important Ensure that the automatic tool initialisation lies planar on the cutting base conveyor belt Adjust the height if necessary gb026 Fig 4 32 Adjusting the height Automatic tool initialisation 3 Table 2 Cutting base 4 Adjusting screw gt Turn the adjusting screw anti clockwise gt Place the automatic tool initialisation on the cutting base gt Use the adjusting screw to set the gradient so that the automatic tool initialisation is in a plane position on the cutting base 4 46 000010 09 11 2009 jmu G3 Series Controls and operation Automatic tool initialisation AKI 493 initialisation Example Module 2 electrical oscillating tool Fig 4 33 Initialisation Use the travel keys to move the module into the centre of the cutter Remove the automatic tool initialisation from the holder and position it in the guide on the table D D Press the tool initialisation to be planar on the cutting base Use Auto init 1 1 2 2 to select the function for automatic initialisation g a The tool is positioned via the automatic tool initialisation and the initialisation process is started The value that is determined is saved for the specific tool 000010 09 11 2009 jmu 4 47 Controls and operation G3 Series Laser
48. 2 2 1 8 2 3 1 8 3 1 8 3 1 Description to follow Board feeder on Description to follow Board feeder off Description to follow Hold down functions Setting the material hold down Depending on the application and the size of the table either a turbine vacuum generator or a gas ring vacuum generator is used to generate the vacuum See chapter Controls and operation Vacuum turbine Settings of the vacuum turbine Status Activating deactivating the turbine vacuum generator Start time Determines the interval in milliseconds between the switching on of the vacuum and the processing of the job This ensures that a vacuum is available once the job processing has been started Stop time Determines the interval in milliseconds from the shutting off of the vacuum until there is no longer a vacuum on the table Calc reset time No function Vacuum pump options Setting of the gas ring vacuum generator Status Activating deactivating the vacuum generator Start time Determines the interval in milliseconds between the switching on of the vacuum and the processing of the job This ensures that a vacuum is available once the job processing has been started Stop time Determines the interval in milliseconds from the shutting off of the vacuum until there is no longer a vacuum on the table Vacuum range Setting of the vacuum width See chapter Controls and operation Material hold down Vacuum range For machine
49. 2009 jmu G3 Series Safety Risk of burns 3 14 3 Cuts and stab wounds 3 15 Knives routers and punching inserts have very sharp edges which are sometimes hidden by moving equipment slipper spring Possible consequences e Cuts and stab wounds to the hands and arms Precautions during the knife change initialisation and the operation in the ONLINE operating status of the machine e Be extremely careful when changing the tool inserts Donot enter the working area during the initialisation and during operation in the ONLINE operating status Risk of burns Certain materials metals and tools router reach very high temperatures during processing Possible consequences Burns on the limbs Precautions Allow workpieces to cool before removing them e Wear suitable protective gloves when removing workpieces that have just been processed e Allow tools router knife to cool before removing them 000011 08 11 2009 jmu Safety G3 Series Electrical hazard 3 16 Electrical hazard Warning Risk of death or injury from electric shock The machine is operated with a mains voltage of 380 V system frequency of 50 60 Hz Safety instructions e Only trained service personnel are authorised to open switch boxes and electro nics units Ensure that mains cables are protected against mechanical loading and are laid so that they are free from strain e Replace damaged cables immediately
50. 35 6 EN ISO 12100 2 Important EU standards and guidelines which are applied are listed in the declaration of conformity In the interests of our customers we reserve the right to make changes as a result of technical improvements This document therefore corresponds to the technical status of the product supplied and not the manufacturer s current state of development CE marking Within the EU the cutter system is delivered with CE marking and an EC declaration of conformity according to Annex II A of the EC Machinery Directive 2006 42 EC see chapter Documents Important If the purchaser adds additional devices to the cutter system or if the system is integrated into an larger system then the device is supplied with a Declaration for the installation of an incomplete machine according to Appendix II A of the EU 000009 06 11 2009 jmu Introduction G3 Series Standardisation tests marking Machinery Directive 2006 42 EC and or without CE marking As a result the declaration of conformity must be issued again by the purchaser 1 6 3 UL testing Z nd G3 cutters have been UL tested and comply with the ISO 60950 standard The certification can be accessed under UL number E176661 C UL US LISTED UL 60950 1 6 000009 06 11 2009 jmu G3 Series Introduction 1 7 1 8 1 9 Legal notice Legal notice The information contained in this publication is intended for information purpo
51. 46 3XL 3200 2293 2 16 000003 06 11 2009 jmu G3 Series Product description Technical information 2 8 1 2 Cutter extension Important Cutter extensions do not increase the work surface of the cutter They serve as a transport belt extension for the feeding and removal of material Fig 2 10 Cutter extension dimensions o o o o le e les Cutter extension T1 3 2 IIA a A A E Type in Sis 313 1 2 4 3515 CE0800 29 33 Q Q Q O CE1250 47 04 Q OQ CE1600 16 82 Q QO O 0 0 90 90 O CE2500 96 26 O O CE3200 123 82 Q Q Q Q 000003 06 11 2009 jmu Product description G3 Series Technical information 2 8 2 Electrical connection power consumption Electrical connection 400 V 50 60 Hz Value Units Voltage 3 phase 400 V L1 L2 L3 N PE Mains frequency 50 60 Hz Power consumption 3 phases without 3 6 IKW vacuum generator Current consumption 3 phases without max 12 A vacuum generator Mains fuse min 16 A Electrical connection 200 V 50 60 Hz Value Units Voltage 3 phase 208 V Mains frequency 50 60 Hz Power consumption 3 phases without 3 6 IKW vacuum generator Current consumption 3 phases without max 12 IA vacuum generator Mains fuse min 16 A 1 only applies for the basic device the minimum requirement for the mains fuse increases depending on
52. 85 dB A is exceeded noise protection measures may be necessary Important Protective measures against noise and emissions dust solvents material residues etc for each tool system are specified in chapter 3 Electromagnetic emissions The G3 series meets requirements of the following technical standards EN 61000 6 2 EMC interference resistance in industrial environments EN 61000 6 4 EMC emission standard in industrial environments Please ask the manufacturer if you wish to refer to the test reports FCC approval NOTE This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide 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 expense NOTE Changes or modifications made by the user that are not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment 000003 06 11 2009 jmu 2 21 Product description G3 Series Technic
53. A01 0x00015B01 0x00015E01 0x00016002 0x00016202 0x00016402 0x00016502 0x00016602 0x00016702 0x00016901 0x00016A01 Error messages Contact service Parameter successfully set to the default value Contact service Formula parameter successfully saved Contact service Press the ONLINE key to repeat the output Cause Message to the user after the replot command The user will be prompted to press the Online key so that the replot can be carried out Curve vector length too short Contact service Error when setting a sub instruction Contact service Incorrect serial interface parameter Contact service Incorrect Z axis parameter Contact service Table number not in the area Contact service Table ID not in the area Contact service No basic settings available Contact service Different versions of the settings Contact service 000012 11 11 2009 jmu Malfunctions G3 Series Error messages 0x00016B03 0x00016C01 0x00016D02 0x00016E03 0x00016F01 0x00017103 0x00017301 0x00017402 0x00017502 0x00017704 No HAL file found Contact service The database was empty during start up Contact service No response from the module carriage Contact service Communication lost Contact service HAL file successfully transferred Restart plotter Contact service Temperature too high in the electronics unit The system ma
54. Description Specification Loctite 243 000001 10 11 2009 jmu G3 Series Cleaning and maintenance 7 4 Steps for maintenance Steps for maintenance Different types of symbols circle box star solid circle box star outline divide the service and maintenance tasks into two groups Meaning of symbols Outline symbols O O e This service and maintenance work is carried out by authorised service person nel of Z nd Systemtechnik Solid symbols W e Service and maintenance work is the individual responsibility of the company operating the machine or its operating personnel Important If necessary carry out work before the stated intervals Change worn parts before the specified intervals as well 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Steps for maintenance acne pala Scares Work to be carried out Ta o By personnel By authorised maintenance personnel S e e One off activity O One off activity SS ic E Repetitive interval O Repetitive interval gt F 5 E xk If necessary Y If necessary 8 As 2 6 General a Visually check the machine for damage n Free the machine of dust and processing residue a Check electrical equipment options to ensure they function a O Check correct functioning of the emergency st
55. Description of menu G3 Series Description of menu The allocations and settings of the tools are carried out in the following submenus 1 2 Module 2 Menu with settings for module 2 Fig 5 9 Module 1 3 1 2 1 Tool pos 1 1 2 Fig 5 10 Tool slot tool assignment e g Module 2 tool 1 1 Module 2 UM tool slot 2 Tool pos 1 2 Oscillating tool tool 1 Each module consists of up to four tools e g PUM The first figure of the menu entry shows the tool slot of the module the second figure shows the tool position The menu entries of the tools 11 14 21 24 31 34 41 44 are identical The allocations and settings of the tools are carried out in the following submenus 5 16 000015 040 11 2009 jmu Description of menu Description of menu Menu with settings for module 3 Tool pos 2 2 See tool pos 1 1 Tool pos 2 3 See tool pos 1 1 Module 3 Fig 5 11 Module 1 3 Tool pos 1 1 1 2 2 1 2 3 1 3 3 G3 Series 5 17 a Tool pos 1 tool slot 2 9b 125 Fig 5 12 Tool slot tool assignment e g Module 2 tool 1 1 Module 2 UM 2 Oscillating tool tool 1 000015 040 11 2009 jmu Description of menu G3 Series Description of menu 1 3 2 1 3 3 1 4 1 4 1 Each module consists of up to four tools e g PUM The first figure of the menu entry shows the tool slot of the module the second f
56. Determines the possible uses of the machine The machine is intended for use as an output device for CAD CAM data for the labelling and processing of materials arranged on the table The intended use and the limits of the application are dependent on The module and tool system that is used The existing material transport system Any other use or any use going beyond this scope constitutes improper use The user bears sole liability for any damage arising as a result of improper use The operation of the machine is also seen as correct if All nationally imposed safety regulations are complied with e The safety instructions in this operating manual are observed The operating conditions are adhered to and the prescribed materials are used Examples of improper use Improper use of the machine can e Cause injury e Result in serious damage to the machine e Lead to loss of warranty Improper use of the machine includes among other things Any structural modification to the machine carried out without written agreement from the manufacturer Use of unsuitable modules tool inserts e Servicing work performed by untrained or unauthorised personnel e Installation of spare parts and use of accessories and resources not approved by the manufacturer e Deliberate or careless interference with the machine during operation e Commissioning of the machine Without sufficient personal protection equipment Without the designat
57. Digital flatbed cutter G3 series M 1600 M 2500 L 2500 L 3200 XL 1600 XL 3200 2XL 1600 2XL 3200 3XL 1600 3XL 3200 Operating manual i ZUND swiss cutting systems Original operating instructions Author Technical Editorial Department Zund Systemtechnik AG Composition and Zund Systemtechnik AG publication Copyright Z nd Systemtechnik AG Version 07 Menu version 1 43 Date 11 2009 Doc no 5106015 G3 Series Contents 1 IntrOduUCHION cacon a Ada we 1 1 1 EOre Word Sr tx tok ett ea reteset ele A ei ales Ae ee ce 1 1 2 Using the documentation asana anaana aaan eee 2 1 2 1 Structure of the operating manual aaua aeaaee 2 12 2 SYMONS 2 cect cv eee ey eee oP ed ee dee Hi ew a 3 1 3 Points to note when reading this operating manual 4 1 4 Care of the documentation 2000 00 eee eee 4 1 5 Current status of documentation 20200 eee e eee eee 5 1 6 Standardisation tests marking 0002e cence eee eee 5 LO Standards 25 254 cc tebe sie ws dank aS ele ates See eee 5 TEZ CEIMArkiIND saciar se adi kA BEG oe be oR hanna 5 1 6 3 UL TOStING wos cock eet cece dod ied now ev bd cet cb eden dies 6 1 7 Legal NOCE sit id AA a oe a ne ated eae ig aad oll Sauce a 7 1 8 Troubleshooting hints and tips 00000 eee eae 7 1 9 Documented cutter models 00 0000 eee eee eee 7 1 10 Publishing details Cr eree
58. FF04 0x00011501 0x00011602 0x00011702 0x00011B03 0x00011C04 0x00011E03 0x00011F02 Cause An incorrect user code was transmitted Access has been denied The 24 VF voltage could not be measured on the BasisFunctionBoard The version of the saved database that has to be loaded is not compatible with the current software Contact service System is already in the required operating status Cause System is already in the initialisation status It is not possible to change the operating status Cause It is not possible to change directly from the current status to the required status For example it is not possible to change directly between the operating status ONLINE and the initialisation status Solution First set the correct status Stop factor overwritten Contact service An instruction could not be restored Inform the manufacturer of this error Contact service Err during init of X amp Y axes Curve axis 0s Init state 1s Incorrect key allocation to the axes Change configuration or use new software ver sion Contact service The command may not be carried out in this operating status Change the operating status in order to carry out the command 6 10 000012 11 11 2009 jmu G3 Series Malfunctions 0x00012103 0x00012902 0x00012A03 0x00012B03 Error messages Cause The instruction was discarded because it is not permitted in the current instruction m
59. G3 Series 000006 04 06 2009 jmu 12 G3 Series Additional specifications 12 Additional specifications 000008 04 06 2009 jmu 12 Additional specifications G3 Series 12 2 000008 04 06 2009 jmu 13 G3 Series Documents 13 Documents 13 1 000029 03 06 2009 jmu 13 Documents G3 Series 13 2 000029 03 06 2009 jmu G3 Series 14 Glossary 14 Glossary User level The menu has a hierarchical division into user levels Each user level can be activated by entering a password Operating status ONLINE Jobs are processed in this operating status Operating status OFFLINE In this operating status data are received but not processed In this operating status it is possible to use remote controlled commands to switch to the operating status ONLINE Operating status STOPPED No data are received in this operating status Cursor Entry marker in the editor for the purpose of entering text or figures Display The display field of the operating unit DOCUTOOL The DOCUTOOL gives a graphic representation of the menu tree There is a help section that can be clicked for each menu entry System requirements Intel Pentium 2 activated Java Script Travel keys Move the module carriage in the OFFLINE mode Simultaneously pressing the SHIFT key increases the movement speed Function keys These keys F1 F8 can be defined by the user Menu entries are assigned to th
60. a a compressor The connection data and connection procedure may be found in the operating instructions for the appropriate tool module Important Always use a stopper to protect connection P4 from dirt in the air supply If particles of dirt reach the tool it will be damaged Interface unit connections SS Fig 4 23 Interface unit connections P1 PUM NOM Punch notch module P2 Various tools with a working pressure of 0 6 MPa P4 POT 4 34 000010 09 11 2009 jmu G3 Series Controls and operation 4 6 8 Activating a module Operation It is often useful to activate a module tool in order to check settings This function can only be carried out in the main menu Activate the required module Module Key combination Module 1 Shift 1 Module 2 Shift 2 Module 3 Shift 3 ICC Camera Shift 8 Laser pointer Shift 9 000010 09 11 2009 jmu 4 35 Controls and operation G3 Series Operation 4 6 9 Tool positions Example EOT POT universal cutting tool Three tool positions are possible following initialisation i 2 k0007 Fig 4 24 Tool positions ltem position Description Key Signal SHIFT Sy A Park position Moves to the highest position on the Z axis m A Y igs Ov Oy B Up Z pos Zero point Upper position sa Oy Wee C Down Z pos Zero point Lower position Z offset y
61. a timely fashion 00001 1 08 11 2009 jmu Safety G3 Series Mechanical hazards 3 14 3 14 1 3 14 2 Mechanical hazards Gathering retraction Hazards caused by the bar modules or the tool system during gathering and retraction Possible consequences e Cuts bruising and crushing of fingers and hands e Bruising of head and arms e Tearing out of hair Damage to clothing Damage to the machine Precautions during the initialisation and the operation in the ONLINE operating status Do not touch tool head and bar Do not enter the working active area Do not touch table surface and material to be processed Do not lay your hands on side covers Do not lean over the working surface e Avoid leaving long hair loose and wearing loose clothes and ties These precautions specifically apply if the cutter can be switched into ONLINE operating status by the CAD CAM system Gathering impacts of foreign objects Foreign objects on the table are grasped and pushed away by the bar and the tool head Possible consequences e Facial injuries and other injuries due to objects being pushed away Damage to the machine Precautions during the initialisation and the operation in the ONLINE OFFLINE operating status Do not place materials tools or other objects on the table or side covers Before operation check whether there are any objects on the table or the side covers 3 18 000011 08 11
62. ach Constant and intensive cooperation with successful users is a prerequisite for innovative and practical solutions We are therefore grateful for any comments or suggestions on how we can improve Contact Z nd Systemtechnik AG Industriestrasse 8 CH 9450 Altst tten Tel 41 71 757 8181 D Fax 41 71 757 8191 E info zund com mail www zund com 000009 06 11 2009 jmu Introduction G3 Series Using the documentation 1 2 1 2 1 Using the documentation The instruction handbook supplied is intended to help you to Operate the machine safely Perform routine machine maintenance Use the machine optimally in all permitted areas To do this you need to be able to find what you want within the documentation The instruction handbook comprises Volume 1 Operating manual This volume contains information on the engineering installation operation and maintenance of the basic machine The technical documentation for the service personnel is contained in volumes 2 and 3 Volume 2 Service manual This volume contains information on the structure of the machine and on servicing by authorised service personnel Volume 3 Spare parts catalogue See Z nd homepage Structure of the operating manual The operating manual consists of individual consecutively numbered chapters These sections are arranged according to the ring binder tabs The table of contents provides informati
63. afety is obligatory during maintenance and cleaning work Keep unauthorised personnel well away from the machine during maintenance work If possible clearly attach a DO NOT SWITCH ON sign to the machine s main control panel during maintenance and cleaning work Express approval must be obtained before carrying out welding or grinding work on the machine Safety data sheets of the resources used can be found on the Z nd homepage General safety instructions on handling chemicals can be found in the section Safety Handling and storage of chemicals 7 2 000001 10 11 2009 jmu G3 Series Cleaning and maintenance 7 3 7 3 1 Operating resources Operating resources Handling operating materials Following the instructions for handling operating materials carefully will increase the reliability and service life of the machine Follow the regulations for handling chemicals particularly cleaning fluid and lubricants Environmental protection Always take care to protect the environment e Observe the disposal regulations applicable in your country e Dispose of spent operating materials correctly Disposal This concerns spent materials such as lubricants adhesives water oil mixtures maintenance unit and all devices that were in contact with these materials e Observe the rules on environmental protection when disposing of spent materi als Collect and store all spent materials separately in
64. al information 2 22 000003 06 11 2009 jmu G3 Series Safety 3 1 General Safety General Your safety as the operator service engineer or otherwise is the primary concern Certain situations problems or faults that may occur on the equipment could put your safety at risk if you are not aware of the steps you should take to avoid the resulting dangers Contents Stipulation of the correct use of the machine Generally applicable safety instructions and safety regulations to be observed Explanation of the meaning of symbols and pictograms which are used in this manual and in signs on the machine Location of safety and monitoring devices on the machine Information on protective equipment required and of requirements for operators and maintenance personnel Specific activity related and situation related safety instructions are given in the corresponding procedures in the following chapters of this manual and in other parts of the documentation Latest technology The supplied machine meets the standards of the latest technology at the time of delivery However the equipment may pose dangers unless the safety instructions in this guide are observed and implemented 000011 08 11 2009 jmu Safety G3 Series Proper use 3 2 3 3 Proper use The proper use of the machine is essential for its safe operation The equipment supplied e Is listed and labelled
65. anism and a metal belt The construction ensures that the function is backlash free and it also minimises wear on the drive system The module carriage is supplied with control signals and compressed air via an energy chain All drive parts are protected against direct access contamination using covers Z axis height adjustment of the module Machine controlled setting of the processing height e g universal module T axis rotary movement of the module Modules with integrated T axis e g universal module 000003 06 1 1 2009 jmu Product description G3 Series Technical description 2 7 5 Processing materials The multitude of materials which can be processed with the different module and tool systems means that there is no single way to achieve the target However the following factors always play an important role and must always be set selected for the specific material e Selection of the module and the tool insert e Selection of the knife router Descending speed descending acceleration Cutting speed acceleration Contact your Z nd partner or the Z nd customer information centre for more precise information 2 14 000003 06 11 2009 jmu G3 Series Product description 2 8 Technical information 2 8 1 Dimensions and weights 2 8 1 1 Basic device Fig 2 9 Basic device dimensions Technical information Type Work surface 1 Overall dimensio
66. ation setup Communications settings for parsers interfaces 5 2 Serial interface Communication settings for the serial interfaces 5 2 1 COM 1 Important If communications software front end terminal is used the communication settings for COM 1 must match those for the communications software Communications settings for COM 1 5 2 1 1 Baud rate The baud rate defines the data transmission speed 5 2 1 2 Data bits Number of data bits during data transmission 5 2 1 3 Stop bits Define the number of stop bits Stop bits signal the end of a data word The choices are e 1 e 2 5 2 1 4 Parity Define parity type Parity is used to detect erroneous transfers The choices are None e Uneven Even 5 2 1 5 Protocol Define protocol transfer The choices are e Hardware e Software None With none data may be lost 5 2 2 COM 2 Communication setting for the COM 2 serial interface 5 3 Ethernet Definition of the ethernet interface for communication with a PC 5 3 1 Tool connector Entry of the port number 5 40 000015 040 11 2009 jmu G3 Series Description of menu Description of menu HPGL port 50000 5 3 2 IP address Display of the IP address 5 3 3 IP template Display of the network template 5 3 4 Unused Display of the MAC address 5 3 5 Set IP address Entry of the IP address This address must correspond with the network IP address The IP address 5 3 5 1 Byte 1
67. ave panel settings Saves all settings for the operating unit 6 9 Restore panel settings Resets all settings for the operating unit to a basic value 6 10 Panel version Displays the current version of the operating unit software 6 11 Panel Displays the status of the operating unit 6 12 Keyboard test This test enables any defective keys to be located The test can be carried out for all keys except the ss key 5 42 000015 040 11 2009 jmu G3 Series Description of menu Description of menu 2 1 oho o ERA 31 8 Th 11 3 9b264 Fig 5 24 Keyboard test 1 Control segments of the travel keys 3 Keyboard code 2 Control segments of the operating keys Press key Y the corresponding control segment of the keyboard test is highlighted and the key code is displayed Problem solution When pressing a key the key code is not displayed or the corresponding control segment is not highlighted gt the key is defective contact your service partner 000015 040 11 2009 jmu 5 43 Description of menu G3 Series Description of menu 8 System info settings Display of general information about the cutter 8 1 Table type Display of the table type e g L 2500 8 2 Table number Display of table number 8 3 Options Installed options are displayed via a numerical code 8 4 Serial number Display of the serial number 8 5 Software versions Displays the current version of the software 8 5
68. avigation keys 9 SHIFTkey 4 Numerical keys 10 Travel keys 5 VAC key vacuum 11 Tool up down key 6 Coordinate system axes 12 Function keys 4 3 000010 09 11 2009 jmu Controls and operation G3 Series Controls 4 3 1 2 Navigation keys AS NN E be Fig 4 3 Navigation keys Key Function in the cutter menu A V Use these keys to navigate through the menu e If submenus are available use this key to change to the next menu level D e Select setting function Change from a submenu or a setting to the previous lt menu level Key Function in the editor lt E Use these keys to move the cursor to the right or left 4 3 1 3 Numerical keys Fig 4 4 Numerical keys Functions of the numerical keys Direct entry of the menu number Entry of values when there is a prompt 4 3 1 4 Function keys Fig 4 5 Function keys Important functions are distributed to the function keys and therefore can be selected directly It is possible to programme the respective function of the function keys 000010 09 11 2009 jmu G3 Series Controls and operation Controls 4 3 1 5 Travel keys 1 B 3 2 Fig 4 6 Travel keys shift key 1 Move module forwards 4 Move module to the right 2 Move module to the left 5 SHIFT key 3 Move module backwards These keys are used to move the module unit in the operating statuses STOPPED and OFFLINE If work is being carried
69. cautions for service personnel The reliability readiness and service life of the machine greatly depend on you carrying out your work in a conscientious manner Important Specialist knowledge and expertise are required to service and maintain the machine The manufacturer provides this knowledge through training courses which are specially tailored for service personnel Only personnel with Z nd certification are permitted to carry out service work on Z nd cutters 3 25 Disposal Disposal Information about proper disposal e Identifies toxic substances that are harmful to the environment e Relates to the disposal of harmful substances e Warns against disposal with domestic waste or environmental pollution caused by hazardous substances and objects contaminated with such substances Measures for disposal Z nd cutters correspond with the requirements of the German Electrical and Electronic Device Act and generally do not contain any poisonous substances or consumables Contact Z nd customer services or your service partner before you dispose of your cutter Dispose of cutting waste in accordance with current national environmental protection regulations In case of doubt check the appropriate disposal methods with your local collection point or recycling centre 3 26 000011 08 11 2009 jmu G3 Series Controls and operation 4 1 4 2 General Controls and operation General This chapter familiarise
70. cessed at the zero point of the work surface Use a tarpaulin airtight material to cover the excess vacuum area 4 38 000010 09 11 2009 jmu G3 Series Controls and operation Material hold down 4 7 2 Defining checking the vacuum range Fig 4 27 Defining the vacuum range Defining the vacuum range Use the key to change to menu Hold down functions3 1 Select function Vacuum range 3 1 1 7 Use the travel keys to approach the left edge of the material to be processed Choose OK to confirm 2 2 28 The vacuum range has been defined 4 39 000010 09 11 2009 jmu Controls and operation G3 Series Material hold down 4 7 3 4 7 4 Checking the range gt gt gt gt Y Use the key to change to menu Hold down functions3 1 Change to the submenu Vacuum range 3 1 1 7 Select the function Move to vacuum3 1 1 7 4 Choose OK to confirm The active module moves to the defined vacuum width Setting the strength o o o Use the key to change to menu Hold down functions3 1 Change to the submenu Vacuum3 1 1 Select the function Power eveB 1 1 5 Enter the required power level and confirm using OK Switching on off o Use the key to change to menu Hold down functions3 1 Change to the submenu Vacuum3 1 1 Select the function Vacuum on off3 1 1 2 Choose OK to confirm 4 40 000010 09 11 2009 jmu G3 Series Controls and operation Feeding options 4 8 Feedi
71. cted and have read and understood the content of the safety instructions in this chapter will operate and maintain this machine Clearly determines the responsibility of the operators and service personnel as required in the instruction handbook Checks the personal protective equipment of operators and service personnel Is responsible for the safe condition of the machine Ensures that servicing and maintenance is carried out according to the mainte nance schedule Notifies the manufacturer of any accident involving the machine that results in se rious injury or substantial material damage Removes the machine from service immediately if defects arise that are detri mental to its operational safety Operators and service personnel Wear the necessary personal protective gear Halt operation immediately in the event of faults Report any changes which are detrimental to operational safety Keep the equipment clean Check the operation of the emergency stop switches before starting work 3 6 Personnel requirements The operators and service personnel must meet the following requirements Be physically and mentally suitable Be qualified by means of thorough training in the use of the machine Have read and understood the operating manual service manual Be over the age of 16 Have knowledge of first aid and the use of fire extinguishers 000011 08 11 2009 jmu Safety G3 Series Rules and safety at work 3 7 3 8 Ru
72. d If a feed is started the module carriage moves to the starting point of the feed The feeding clamps are lowered and the conveyor clamping elements fix the conveyor belt A feed is executed If the feed length is greater than the length of the work surface this process is repeated until the given length is reached 4 8 3 2 Manual feed The feeding clamps are lowered via the menu 1 7 2 3 Lower the feeding clamps The feed is started with the travel keys After the feed is complete raise the feeding clamps using 1 7 2 3 Ra se feed clamps 4 44 000010 09 11 2009 jmu G3 Series Controls and operation 4 9 4 9 1 Automatic tool initialisation AKI Automatic tool initialisation AKI Important Manual initialisation is described in the operating manual of the relevant tool See chapter Tools Description The following tools can be initialised using the automatic tool initialisation Kiss cutting tool without glide element KCT Universal cutting tool UCT Electrically oscillating cutting tool EOT Pneumatically oscillating cutting tool POT Driven rotary cutting tool DRT Router Attention Risk of damage to the cutter Only use the automatic tool initialisation for compatible tools Carry out manual initialisation for other tools that are not listed O O Fig 4 31 Automatic tool initialisation 1 Holder 3 Automatic tool initialisation 2 Rest 000010
73. der to activate the vacuum element 4 42 000010 09 11 2009 jmu G3 Series Controls and operation Feeding options 4 8 2 Feed guide rail Fig 4 30 Feed guide rail 1 Screw for fixing the feeding clamp 2 Feed guide rail 3 Fastening screw self locking Assembling the feed guide rail gt Use SHIFT BY to switch the cutter off Loosen the screw for fixing the feeding clamps gt Position the feeding clamps gt Loosely screw the feeding guide rail to all feeding clamps using the supplied self locking fastening screws Tighten the screw for fixing the feeding clamps Use r to switch on the cutter Lower 1 7 2 3 and raise 1 7 2 3 the feeding guide rail several times for inspection purposes 4 43 000010 09 11 2009 jmu Controls and operation G3 Series Feeding options 4 8 3 Feeding options The feed is controlled via the communication software The following factors can be preset via the cutter control unit see chapter Menu description and must be set for the specific material Speed settings Accel settings Feeding mode vacuum settings Function of the feeding clamps Feed direction 4 8 3 1 Automatic feed gb371 During automatic feed the feed length is defined If necessary a starting point can also be defined for the fee
74. direction of each test cut act as measuring points for the calculation of the correction values You should therefore observe exactly where the blade penetrates when cutting the 4 lines and mark the penetration points 000015 040 11 2009 jmu Description of menu Description of menu G3 Series Example 1 Start of cut penetration point 2 End of cut Cutting diagram with all correction values set to 0 Cutting diagram once the alignment process has been successfully completed Preparation Place paper on the cutting support gt Switch vacuum on 5 12 000015 040 11 2009 jmu G3 Series Description of menu Description of menu Correct Y When the axes are aligned the cuts are moved towards the coordinate system axes until each of the parallel cuts lie on the same axis Measure and calculate distance a mm in of the parallel cuts to the X axis as follows Start the 7estcuf 1 1 4 4 function Option 1 line 1 has to be moved to Option 2 line 1 has to be moved to Result the left and or line 2 has to be moved the right and or line 2 has to be The cuts lie along one line to the right to lie along the same line moved to the left to lie along the Y1 Y2 a 2 same line Y1 Y2 a 2 a Distance in mm in Y1 calculated value Y2 current value from Correct Y1 1 1 4 3 gt Enter the calculated value Y1 in the Correct Y 1 1 1 4 3 field gt Perfo
75. dule tool insert Menu entries are displayed faded out depending on the module tool combination 5 2 Menu structure The settings for modules and tools are arranged as they are presented in reality Tools are used in a module e g UM and routers knives pens etc are used in the tools The following menus appear in the main menu 1 Cutter settings Module selection Tool selection Initialisation General cutter settings 2 Job settings Reference points window 3 Functions Vacuum Components Router option Tests 4 User settings User level password 5 Communication settings Processing software communication settings front end Cutter 6 Operating unit Language function keys date time 7 Info Information on the cutter operating hours 8 Service Firmware update 000015 040 11 2009 jmu Description of menu G3 Series Description of menu 1 1 5 3 Description of menu Main menu Highest level of the menu structure Cutter setup The following settings for the configuration of the cutter are carried out in this menu Tool settings Manual automatic initialisation Moving speeds Acceleration settings Module settings Tool assignment Work modes Settings for the different movement axes Module 1 Menu with settings for module 1 Fig 5 1 Module 1 3 5 2 000015 040 11 2009 jmu G3 Series Description of menu Descripti
76. e provided for general information and do not necessarily correspond to the latest version of the machine Dimensional information Dimensional information is listed in the SI US unit system according to the place of installation Care of the documentation Volume 1 Instruction manual must always be kept in close vicinity of the workstation Volume 2 Service manual must be made available to maintenance and service personnel when required 000009 06 11 2009 jmu G3 Series Introduction 1 5 1 6 1 6 1 1 6 2 Current status of documentation Current status of documentation Act accordingly to make sure that the documentation is complete and up to date at all times Do not remove parts of the documentation Request copies of missing or illegible pages from the manufacturer or download and print them from the Z nd homepage If any new documentation is delivered as a result of conversions taking place file it away immediately If documentation is changed file the new information and destroy the old Ifthe documentation exists in more than one language ensure that all languages are kept up to date Standardisation tests marking Standards Scope of the documentation supplied Volume 1 Operating manual Volume 2 Service manual Volume 3 Spare parts catalogue Execution This operating manual makes reference to the following standards EN 62079 EN 62023 ANSI 25
77. ea 3 Example Module 2 2 Tool e g EOT b Safety distance Safety distance during the manual initialisation The safety distance b for operating personnel during manual initialisation is 25 cm Do not reach into the danger area during the initialisation phase 000011 08 11 2009 jmu 3 9 Safety G3 Series Working and traffic area 3 10 Working and traffic area Warning There is a danger of injury to others through inappropriate behaviour or carelessness Please advise others to maintain an appropriate safety distance from the designated work and traffic zone Fig 3 4 Working area around the cutter A Working area active area of the tool B Working and traffic area of the operator C Minimum safety distance for other personnel Safety distance for other personnel The safety distance for other personnel extends over the surface of the cutter plus a distance of at least one metre Working and traffic area The working and traffic area extends over the surface of the cutter with fittings and options plus a distance of at least one metre Use with conveyor extension When using a cutter extension the loading and removal of material is permitted outside of the danger zone working and active area 3 10 000011 08 11 2009 jmu G3 Series Safety Safety signs 3 11 Safety signs 3 11 1 Responsibility of the operator Warning Risk of injury due to a lack of safety signs Risks and sources
78. ed in the X direction Y Offset Value by which the output is moved in the Y direction Buffer settings Buffer for the last job received in HPGL format Clear buffer Clear buffer Start replot The last job is carried out again Window settings Limit the working area of the machine clipping All data that are inside outside of this window are ignored Two windows can be defined independent of each other Window 1 options Define window 1 Window settings Switching window on off If the window is deactivated the maximum working area of the cutter is used If the window is activated the defined limits cannot be exceeded in any operating status Safety zone Selection of whether the blocked area is inside or outside of the defined window Inside the area outside of the window is blocked Outside the area inside of the window is blocked Define corner The window range is determined by entering two reference points on the working surface Procedure Use the direction keys to position the active pointer in the lower right hand corner of the required window area and confirm gt Use the direction keys to position the active pointer in the upper left hand corner of the required window area and confirm Show window 5 32 000015 040 11 2009 jmu G3 Series Description of menu 2 6 1 5 2 6 1 6 2 6 1 7 2 6 1 8 2 6 2 2 6 2 6 1 2 6 2 2 6 3 2 6 4 2 6 5 2 6 6 Descri
79. ed protective and safety measures Ifthe operating manual is incomplete or not available in the local language Non adherence to maintenance requirements e Failure to react to signs of wear and damage 3 2 000011 08 11 2009 jmu G3 Series Safety 3 4 3 4 1 Hazard warnings important instructions Hazard warnings important instructions Explanation of the hazard warning Both in the operating manual and on the device itself dangers important instructions and user tips are designated by special symbols and signal words as follows Danger The safety instruction Danger e Refers to an immediate threat e Refers to operational and service risks e Warns of serious effects on health and safety including life threatening injuries Warning The safety instruction Warning e Refers to a dangerous situation e Refers to operational and service risks e Warns of serious effects on health and safety including life threatening injuries Attention The safety instruction Caution e Refers to a dangerous situation e Refers to operational and service risks Warns of minor injuries and other serious damage to the machine and secondary damage Attention The safety instruction Caution without a hazard symbol e Refers to a dangerous situation e Refers to operational and service risks Warns of serious damage to the equipment damage to other property and con sequential damage Important Refers
80. enance schedule 7 16 000001 10 11 2009 jmu Cleaning and maintenance G3 Series jobs intenance Ma Lubricating the lubrication points Fig 7 8 Lubricating the lubrication points Push the bar forwards 7 17 Cleaning and maintenance G3 Series Maintenance jobs 10 0 2 0 10 0 0 08 0 Screw the lubrication connection of the lubrication set onto the guide rails behind the bar A B Press the syringe until the feed line is ventilated Position the guide bearings above the lubrication connection C Use the syringe to insert approx 1 ml of oil into the guide bearing D Move the bar forwards and backwards 10 times over the length of the guide carriage via the lubrication connection E Use the syringe to extract remaining oil Then move the bar forwards F Clean the guide rails using a lint free rag G Remove the greasing set Lubricate the guide bearing on the other side in the same way Fit the covers 7 18 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs 7 7 7 Cleaning oiling Y axis guide rails Tools and materials Lubricant for guide rails bearings X 4 mm Allen key Clean lint free rags Ensure that following preconditions are fulfilled 1 The machine is in the maintenance position 1 All modules have been dismantled from the module carriage Remove the co
81. enu gt Select the required language from the list and confirm Set display Setting the contrast Key Description Shift gt Increase contrast Shift 4 Reduce contrast Switch lighting on off Shift esc must be pressed to switch the display lighting on off Setting the volume of the signal Key Description Shift a Y Increase decrease the volume Delete data buffer Delete the data buffer following the termination processing of a job Menu Description 2 5 1 Delete data buffer 4 16 000010 09 11 2009 jmu G3 Series Controls and operation 4 6 4 6 1 Operation Operation Daily checks prior to start up Attention There is a risk of injury if the machine is defective Faults on the machine may be the cause of malfunctions and accidents never start up a defective machine e Report all defects and faults to your supervisor and arrange for them to be rec tified immediately by qualified personnel Inspection Ensure that all maintenance and service tasks are performed in accordance with the maintenance schedule Before starting up the machine each day perform a walk round of the machine and check the following e Check the machine for visible damage Remove local dirt caused by processing materials and dust Remove objects from the processing table the side supports e Check whether all maintenance and service covers are
82. equipment clothing 3 13 Personal protective equipment clothing The safety equipment required for operating the machine is dependent on the following factors The module and tool system The material to be processed When operating the machine or carrying out maintenance or servicing work wear close fitting clothing and the appropriate personal protective equipment Warning Risk of injury from being caught or trapped in moving machine parts Do not wear loose clothing scarves open jackets or open shirt sleeves e Remove all jewellery before starting maintenance and servicing work Personal protective equipment comprises e Work clothes service personnel e Protective goggles operators service personnel To provide protection from particles during cutting operations To protect the eyes from dangerous radiation To protect the eyes from chemicals e Protective gloves where injury is possible due to Burns Sharp or pointed objects e Chemical resistant protective gloves where injury is possible due to Chemicals cleaning agents e Breathing protection when working with poisonous substances e Ear protection if the continuous sound pressure level is over 80 dB Important You are personally responsible for e Using the required personal protective equipment e Cleaning and maintaining the equipment on a regular basis e Replacing damaged and unusable elements of protective equipment in
83. ese keys HP GL Hewlett Packard Graphic Language HP GL is a programming language developed by Hewlett Packard for controlling plotters Initialisation After the cutter is started key F1 is used to initialise the X Y axis of the cutter The absolute zero point is defined via a light barrier The Z axis is initialised separately for each tool Communication software Front end For example GTK etc user software visual display of HP GL commands Menu entry Each menu entry has a uniquely assignable menu number 000014 05 06 2009 jmu 14 1 14 Glossary G3 Series Menu number The menu is numbered consecutively and hierarchically Modules Modules serve as the interface between the cutter and the tool Emergency stop Emergency stop switches are safety elements which cause the immediate switching off of the machine in hazardous situations Numerical keys Keys for making numerical entries on the operating unit Parser Program that can break down any input and convert it into a format that can be used for further processing Popup Window that is released by the menu Shift key The shift key on the operating unit is used as a switch for short term switching of the keyboard to the second assignment level with special functions Soft keys These special keys change their function depending on the situation and make operation easier Standby The cutter is switched on but not initialised The i
84. essible via a service door so that settings and maintenance work can be carried out 2 12 000003 06 11 2009 jmu G3 Series Product description Technical description 2 7 4 Movement system The G3 series has four electronically driven axes Axis Function Movement system Bar Drive via toothed belt steel belt X Material transport material Feed clamp elements feeding transport extension clamps auxiliary drive Y Movement of the module Drive via toothed belt steel belt carriage Z Height adjustment of the Example Universal module module routing module T Rotary movement of the Example Universal module module X axis bar The bar is driven by a motor via a toothed belt gear mechanism and a toothed belt metal belt combination The construction ensures that the function is backlash free and it also minimises wear on the drive system The bar is supplied with control signals and compressed air via an energy chain All drive parts are protected against direct access contamination using covers X axis material transport The material transport takes place via conveyor clamp elements and feed elements on the bar which move the conveyor belt including the material to be used via the bar movement In the case of large cutters or cutters with material transport extension an auxiliary drive is also used Y axis module carriage The module carriage is driven by a motor via a toothed belt gear mech
85. est cut for the alignment of the T axis Description to follow 1 1 1 4 6 Cut polygon test Test cut in the shape of an octagon Description to follow 1 1 1 4 7 Cut rectangle test Description to follow 1 1 1 5 Router sys 1 Select router system 1 if two router systems are installed 1 1 1 5 Router sys 2 Select router system 2 if two router systems are installed Tool pos 2 5 14 000015 040 11 2009 jmu G3 Series Description of menu Description of menu 1 2 Fig 5 7 Tool slot tool assignment e g Module 2 tool 1 1 Module 2 UM tool slot 2 Tool pos 1 2 Oscillating tool tool 1 Each module consists of up to four tools e g PUM The first figure of the menu entry shows the tool slot of the module the second figure shows the tool position The menu entries of the tools 11 14 21 24 31 34 41 44 are identical The allocations and settings of the tools are carried out in the following submenus Tool pos 1 3 gb125 Fig 5 8 Tool slot tool assignment e g Module 2 tool 1 1 Module 2 UM tool slot 2 ae Tool pos 2 1 2 Oscillating tool tool 1 Each module consists of up to four tools e g PUM The first figure of the menu entry shows the tool slot of the module the second figure shows the tool position The menu entries of the tools 11 14 21 24 31 34 41 44 are identical 000015 040 11 2009 jmu
86. g Kl beroil 4UH1 Fig 7 1 Lubricating points Place of lubrication Amount Cause Module carriage 2x Right hand bar guide 2 x Guide rails and guide bearings Left hand bar guide 2x 7 6 Accessories case The accessories case contains useful tools and equipment for the operation or maintenance of your machine 7 8 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Accessories case Contents Accessories Amount Activity Allen screwdriver 4 x 170 mm Qty 1 Assemble disassemble modules Vacuum element spacers Qty 6 Service Installation Adhesive tape width 19 mm Qty 1 Service Installation Teflon grease 20 ml Service Soldering fluid brush Qty 1 Service Plier stapler Qty 1 Change conveyor belt Applicator gun KPM 250 ECON Qty 1 Change conveyor belt Adhesive tape double sided Qty 1 Fix cutting base Special guideway oil 2 x 25 ml Lubricate X Y axis guide rails guide bearings Greasing set for X axis guide rails Qty 1 Lubricate X axis guide rails bearings 1 Accessories for machines with conveyor 2 Accessories for machines with cutting bases 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs 7 7 Maintenance jobs 7 7 1 Service flaps and covers Fig 7 2 Service flaps covers Item Description Task 1 Cover Oil and clean t
87. he covers have been fitted Fit any covers that are missing 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs 7 7 4 Clean the machine Z nd cutters are production machines that are subject to enormous amounts of stress on a daily basis Keeping the machine clean will help to keep operation as free from interruption as possible Important Do not use compressed air to clean the machine Loose cuttings and other dirt will end up in the bearings and drive belts and damage them Attention Danger of damage Incorrect cleaning products and methods will damage the machine e Only use gentle cleaning agents and plastic maintenance products for cleaning Never clean the tool using ultrasound a steam jet compressed air etc Procedure e Clean the table operating unit all covers and panels with a plastic maintenance product at regular intervals weekly e Regularly daily remove all materials residues from the table the tools and mo dules e Keep the environment clean free from material residues dust 7 12 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs 7 7 5 Clean X axis guide rails Tools and materials Lubricant for guide rails bearings Clean lint free rags X 4mm Allen key Ensure that following precondition is fulfilled 1 The machine is in the maintenance position Remove the covers Fig 7 4 Remove the covers
88. he left hand guide rails 2 Cover Oil and clean the right hand guide rails 3 Cover Oil and clean the module carriage guide rails 4 Maintenance unit access Drain the condensation water set the pressure 5 Power unit cover Fuses 6 Cover Change conveyor belt vacuum generator access Important For reasons of safety all other covers should only be opened for service work by Z nd staff of people authorised by Z nd 7 10 000001 10 11 2009 jmu G3 Series Cleaning and maintenance 7 7 2 7 7 3 Maintenance jobs Maintenance position Warning Danger of injury The cutter may be put into operation by third parties Always place the cutter in the maintenance position before carrying out mainte nance work Unless expressly required otherwise move the machine to the maintenance position before starting maintenance work gt Sp WN Fig 7 3 Secure the machine Switch off the machine using the main switch Protect the machine against unauthorised start up block the on off switch with a lock Visually inspect the machine for damage Attention There is a risk of injury if the machine is damaged Before daily commissioning ensure that there is no damage to the machine Never start up a damaged machine Have damage repaired immediately by authorised service personnel Daily checks e Walk around the cutter and check the machine for damage Make sure that all t
89. he manual initialisation Stop angle Ifa change in direction larger than the set angle is determined during movement then the speed is reduced to zero before movement is started in the new direction 9b131 Fig 5 4 Stop angle A Processing direction Stop angle amp Direction change angle Quality Setting of the processing quality Important e The quality setting corresponds with the HPGL command QU e If the quality is set via this menu the following parameters are automatically op timally set acceleration circle res e Send the circle data as an arc function Selection Description High Low acceleration high quality Normal Medium acceleration medium quality 5 6 000015 040 11 2009 jmu G3 Series Description of menu 1 1 1 3 2 4 1 1 3 2 1 1 1 1 3 2 2 1 1 1 3 2 3 1 1 1 3 2 4 1 1 1 3 3 1 1 1 3 3 1 1 1 1 3 3 2 Description of menu Selection Description Low High acceleration low quality Level 4 Level 5 Level 6 Level 7 Level 8 Level 9 Speed settings Setting of the movement speeds for the tool that is in use The possible moving speed is dependent on the knife router pen being used and on the material to be processed Up X amp Y Moving speed in the directions X and Y when the tool is raised Adjusting value 1 1000 mm s Down X8 Y Moving speed in the directions X and Y when the t
90. he module change should be carried out Position 1 Module change in Position 1 Position 2 Module change in Position 2 Position 1 and Position 2 After selecting function 1 5 1 Change module the user can choose between Position 1 and Position 2 4 28 000010 09 11 2009 jmu G3 Series Controls and operation Operation Module mount Fig 4 19 Module mount 1 Locking mechanism 3 Electrical connection 2 Mounting ledge 4 29 000010 09 11 2009 jmu Controls and operation G3 Series Operation Inserting replacing the module e g UM Fig 4 20 Inserting a module gt sS g uy Select Change module1 5 1 The module carriage moves to the module change position Position the module on the mounting ledge as shown in Fig 4 20 step A Tilt the module backwards onto the module carriage Lower the module until it stops Use the 4 mm Allen key to fix the module in place The module is now mounted and is located by the software Problem solution The module cannot be lowered gt Loosen the module locking mechanism before insertion 4 30 000010 09 11 2009 jmu Controls and operation G3 Series Operation 4 6 6 3 Tool e g oscillating tool Ensure that following preconditions are fulfilled 1 The machine is switched off and is in the operating status STOPPED L The module is now mounted and has been located by the co
91. i dias angen A Ged ie ee ed eee T ee A 7 General danger area ooooccncccon teens 7 Danger area on the module carriage 2 0 0c ee eee 8 Danger area during the installation 0 2 00 0 eee eee 9 Working and traffic area 2 ee 10 SafetySIQNsS 22 Sesion A e fo Sete ea 11 Responsibility of the operator 22000 0c cee eee eee 11 The signal Words eskat cnc ee a eee ee 11 Position of the safety Signs 0 0 ee ee 11 Safety and monitoring devices 2 000 ee 14 Protective System cion e eit eee dd 15 Operating Unitat eo eae Ret a he ete to oe 15 Emergency stop switch krena ka E 0 00 cece ee eee 16 Safety cut off feature 2 ee ek ee ee ee ee eee 16 Personal protective equipment clothing 25 17 Mechanical hazards 0 000 cece eee 18 Gathering retraction ooooooocooooooo eee 18 Gathering impacts of foreign objects 2 0 0 0 18 Cuts and stab wounds oes risi orie e EESE AREER E EAE RR 19 RISOUL a 19 Electrical hazard i i ecien ii i eee de Et da 20 Risks arising from the emission of toxic dust ooooooooooo 21 Risks arising from the processing of toxic hazardous materials 21 Environmental hazard 000 000 c cece eee ee eee eee 22 Handling and storage of chemicals 220000002 ee eeee 23 Risk of fire and explosion 0000 e eee eee eee 24 Danger caused by laser beam laser pointer
92. i oldie eA eal Md tare aoe bt A 16 4 5 3 Setting the volume of the signal 00 00 e eee ee 16 4 5 4 Delete data buffer 0 eee 16 46 Operation Iaido oe tees a ele alla he a Be Mae glade do i d 17 4 6 1 Daily checks prior to start up 000 00 eee eee 17 46 2 Start ups 444 eied dead rios andrade 18 4 6 3 Operating status 2 0 e a e EN EA ee 20 4 6 3 1 ORFLINE r PE Pee eed Pace es e Peet 21 4 06 32 STOPPED via iia a awe BAe bina 21 40 33 ONLINE sia npn ti ii ann eae a Bee ets 22 4 6 4 Moving the bar module manually 2 0 0 e eee eee 23 4 6 95 Tool handling acia a as 24 4 6 6 Modulesitools seccion id cea koe een ete mad a Wed dinar ans 27 ACA ate RE aie AE Re a RE tha Baa aE aie ee 27 4 6 6 2 Inserting replacing the module 1 tte 28 4 6 6 3 Tool e g oscillating tool oi tee 31 4 6 7 Connecting driven tools allocating port 0000000 32 4 6 7 1 Connection electrical tools EOT DRT ete 0 00 es 33 4 6 7 2 Connect pneumatically driven toolS 0 ee 34 4 6 8 Activating a module 0 ce eee 35 4 6 9 LOOl POSITIONS 6 344 eked a ld eee ad Gl a 36 4 7 Material hold down 0 000 cee eee 37 4 74 Pr paration star ad ar tad et weed 38 4 7 2 Defining checking the vacuum range o ocoocccccc ee 39 4 7 3 Setting the strength sssri sopua ko ee ees 40 AFA Switching On Off aora lc de Gee A SA eat 40 4 8 Feeding Options esis
93. ice The sequencer task has not started The Altera is therefore not ready Contact service Unstable controller parameters Axis 0s Error 1s i params 6 26 000012 11 11 2009 jmu G3 Series Malfunctions 0x0001E101 0x0001E201 0x0001E303 0x0001E401 0x0001E801 0x0001E904 0x0001EA01 0x0001EB01 0x0001EC02 0x0001ED03 Error messages 0x0001 neg high param 0x0002 pos low param 0x0004 high smaller than low v Params0x0100 0x0200 0x0400 Contact service Vacuum generator error Contact service Vacuum generator not ready Contact service Timeout during switching of the tool connection Contact service Pump switch on error Contact service Pump switch off error Contact service A status bit in the Z link has been occupied twice Contact service No pump or valve available to switch on Contact service HW must first be allocated to an option board Contact service Tool not inserted in conn 0s Contact service Excess temperature of the X axis motor Cause An excessive temperature was measured on the X motor 000012 11 11 2009 jmu 6 27 Malfunctions G3 Series Error messages 0x0001EE03 0x0001EF03 0x0001F201 0x0001F301 0x0001F401 0x0001F501 Solution e Wait until the temperature has cooled down e Check the sensor Excess temperature X axis motor Cause X motor displays an excess temperature Solution Wait
94. ignificant risk to health e Never process toxic hazardous materials Obtain information from the manufacturer of the material to be processed about its toxicity Guidelines e The company operating the system is responsible for establishing which proces sing materials are toxic hazardous e Itis prohibited to process toxic materials on Z nd cutters without appropriate ad ditional safety measures e The company operating the system is responsible for installing appropriate addi tional safety measures 000011 08 11 2009 jmu 3 21 Safety G3 Series Environmental hazard 3 19 Environmental hazard Warning Processing residues operating fluids etc can cause damage and pollute the environment if they enter the soil watercourses or the sewage system Explanation of the hazard label Hazard label for substances that are harmful to the environment Safety regulations and protective measures e Dispose of waste materials in accordance with current national environmental protection regulations In case of doubt check the appropriate disposal methods with your local collection point or recycling centre e Collect different chemicals in separate containers 3 22 000011 08 11 2009 jmu G3 Series Safety 3 20 Handling and storage of chemicals Handling and storage of chemicals Warning Cleaning agents operating fluids etc can cause skin irritation and can therefore be hazardous to
95. igure shows the tool position The menu entries of the tools 11 14 21 24 31 34 41 44 are identical The allocations and settings of the tools are carried out in the following submenus Tool pos 3 2 See tool pos 1 1 Tool pos 3 3 See tool pos 1 1 Module 4 Menu with settings for module 4 optional Fig 5 13 Module 1 3 Tool pos 1 5 18 000015 040 11 2009 jmu G3 Series Description of menu 1 4 2 1 4 3 1 5 1 5 1 1 5 2 1 5 2 1 1 5 2 1 1 Description of menu 1 2 Fig 5 14 Tool slot tool assignment e g Module 2 tool 1 1 Module 2 UM tool slot 2 Tool pos 1 2 Oscillating tool tool 1 Each module consists of up to four tools e g PUM The first figure of the menu entry shows the tool slot of the module the second figure shows the tool position The menu entries of the tools 11 14 21 24 31 34 41 44 are identical The allocations and settings of the tools are carried out in the following submenus Tool pos 4 2 See tool pos 1 1 Tool pos 4 3 See tool pos 1 1 Module carriage Settings on the module carriage e Change module e ICC Camera e Laser pointer settings Change module Procedure for changing the module See Modules section Sensor Camera Settings for the laser pointer ICC camera Laser pointer settings The laser pointer is an optical instrument for visually determining the reference point The reference
96. il vectors have been processed 000012 11 11 2009 jmu 6 7 Malfunctions G3 Series Error messages 0x0000D204 0x0000D603 0x0000DC02 0x0000DD04 0x0000DE03 0x0000E204 0x0000ED03 0x0000EE02 Ox0000EF02 AD converter error Index 0s Contact service Error in the controller Index 0s Contact service Internal error The allocation for a watch job could not be found Contact service Wrong voltage on amplifier Index 0s Contact service Overload identified Check parameter speed acceleration adjust if necessary Err on axis voltages Axis code 0s Contact service Head within the clipping area Cause It was detected that the head is currently in a hard clipping area This was probably because a hard clipping window was defined at the point where the head is positioned or because a hard clipping area was activated Solution The head must be brought out of this area or the hard clipping window must be defined differently The head can only be moved out of this area manually If an automatic initialisation tool is available then position this back in the park station so that the clipping window is free again HAL Error during the reading of the comm devices in the bus definition HAL file row number 0s Contact service HAL Error during the reading of the device ID in the bus definition HAL file row number 0s Contact service 6 8 000012 11 11 2009
97. ilable on this machine Solution Select valid module CRC error during transfer Cause An error occurred during the examination of the checksum Solution Check communication HAL An attempt was made to access an unknown HAL ID HAL file row number 0s Contact service HAL Attempt made to access an undeclared BusElement ID HAL file row number 0s Contact service Incompl HP GL comm Command 2s is incorrect Cause The HP GL command was called up with too few parameters 6 6 000012 11 11 2009 jmu G3 Series Malfunctions Ox0000AA02 Ox0000AB02 0x0000B902 Ox0000BA04 0x0000BB04 0x0000BC04 0x0000BD02 0x0000C002 0x0000C600 Error messages Solution Check HP GL Manual for the call Unknown XX command Cmd 2s Contact Service HP GL command not supported Cause This HP GL command has not yet been implemented Unexpected error The Altera has already been configured Contact service Error when loading the Altera Contact service N status error before loading the Altera Contact service Altera not ready Contact service HAL Err reading 16 bit value HAL file row number 0s Contact service The response to the command was not received in the expected time Contact service The cutter is not in a permitted operating status for this action Cause The sequencer must be in waiting status for the function which has been called up Solution Wait unt
98. in tabular form all the maintenance jobs which are re quired for the machine The maintenance list only affects the basic unit Maintenance activities for mo dules tool inserts and options can be found in the respective operating manual Maintenance jobs that operators can carry out themselves are specially indicated and are described in more detail in this chapter Important In general no special tools are required for maintenance jobs that operators can carry out themselves All other jobs must be undertaken only by personnel authorised by Z nd or by Z nd Systemtechnik Customer Services or by contractual partners authorised by Z nd Systemtechnik Important Do not exceed the specified maintenance and cleaning intervals You can shorten these intervals if necessary at your own discretion Carry out the maintenance jobs conscientiously at the specified intervals The intervals are given in calendar periods or operating hours Maintenance recommendation The manufacturer recommends that a general inspection of the machine is carried once per year This interval can be reduced in the case of greater utilisation and load to the system Regular maintenance extends the lifetime of the cutter Provide the service technician with the accessories case and ensure that the maintenance work is confirmed Shutting down extended downtimes If the machine is to be shut down for a prolonged period or decommissioned
99. ing Canada USA 3 Max current 2 Voltage range 4 Frequency 2 3 Intended use The cutter system can be used for the following purposes Asan output device for CAD CAM data For processing and labelling materials arranged on the table Aside from this the intended use and the limits of the application are as follows Depending on the tools and material feed system available Described in the chapters Tools Modules and Material transport 2 3 000003 06 11 2009 jmu Product description G3 Series Cutter overview 2 4 Cutter overview 72 Fig 2 4 Cutter overview 1 2 3 4 5 6 7 Work station Cutter extension front Table with vacuum Left hand safety device Bar Cutter extension rear Boom for router option 8 Power unit 9 Right hand safety device 10 Electronics unit 11 Vacuum generator 12 Extractor optional 13 Maintenance unit air pressure setting 000003 06 11 2009 jmu G3 Series Product description 2 5 Modules tools 2 5 1 General Modules tools 7 le gb084 Fig 2 5 Modules tool inserts tools Modules UM RM PUM Tools EOT POT DRT Module carriage Router knife WORN Modules The use of modules and tool inserts means that Z nd cutters can be highly specialised on the one hand whilst still being able to be easily converted for pr
100. installed correctly 000010 09 11 2009 jmu Controls and operation G3 Series Operation 46 2 Start up Switching on the machine Fig 4 12 Switching on the machine gt Switch the main switch to position ON 1 Y The cutter switches on The start page appears on the display 4 18 G3 Series Controls and operation Operation Initialising the machine Attention Risk of injury due to automatic starting of the machine Following initialisation the operating status OFFLINE is active The cutter can receive commands from the operation software which activate the operating status ONLINE gt Only switch on the operation software following the initialisation of the machine gt Press the function key Y The machine is initialised 000010 09 11 2009 jmu Controls and operation G3 Series Operation 4 6 3 Operating status The cutter can be switched into three operating statuses depending on the purpose OFFLINE ONLINE STOPPED A combination of keys can optionally be used to switch from any operating status to either of the other two operating statuses The current operating status is displayed in the header of the main menu and with the LED of the ONLINE key The following graphic illustrates how the desired operating status is activated OFFLINE SHIFT 2 ON LINE STOPPED ONLINE gb040_2 Fig 4 13 activate operating status 4 2
101. ions where fire extinguishers are kept and familiarise yourself with their use The adjacent sign indicates the location of a fire extingu isher Do not use inflammable cleaning agents to clean the machine e Store all processing materials in the proper manner in accordance with local gui delines Danger caused by laser beam laser pointer Class 2 lasers are used as laser pointers Momentary irradiation of the eyes as can occur if you accidentally look directly at the laser is not dangerous In addition depending on the construction the laser beam is targeted directly at the material to be processed Safety instructions Avoid direct prolonged eye contact Safety instructions for operators This instruction manual cannot cover all possible situations and potential hazards It is therefore particularly important that operators have been thoroughly trained and are aware of and able to correctly assess the hazards that can arise from the machine e are familiar with all safety devices on the machine e request information from the manufacturer without delay if an undocumented ha zardous situation arises in connection with the machine In addition to these safety instructions you must also observe the situation related safety notes in the chapters Controls and operation and Maintenance and cleaning 000011 08 11 2009 jmu 3 25 Safety G3 Series Safety precautions for service personnel 3 24 Safety pre
102. itches Attention Risk of damage to the machine Only use the emergency stop switches to switch off the machine in an emergency not for standard shutdown e Emergency stop switches are part of a protective circuit They allow the machine to be switched off quickly in a dangerous situation Fig 4 8 Emergency stop switches The machine is fitted with four emergency stop switches as standard They are located as follows 1x onthe operating console e 3xon the side support covers Consequences of pressing an emergency stop switch The drive motors are brought to a standstill and then are isolated from the energy supply e Safety related units modules tools auxiliary drive sheet feeder etc are isola ted from the energy supply Units that are not safety relevant or that are important for the operation of the de vice vacuum operating unit dust extractor compressor etc remain switched on 000010 09 11 2009 jmu Controls and operation G3 Series Controls Important An emergency stop switch that has been pressed remains locked in the off position To unlock an activated emergency stop switch after regaining operational safety turn the switch anti clockwise Procedure gt When a hazard or a possibly hazardous situation occurs press an emergency stop switch without delay Y All machine movements are stopped The emergency stop switch that has been pressed remains locked in the off position
103. kwards The conveyor clamping elements fix the conveyor belt and the feeding clamps are pressed onto the material to be pushed forward The bar tightens the conveyor belt to the set position The shape of the feeding clamps varies depending on the material to be worked with An auxiliary drive is used in the case of larger tables or processing materials that are heavier for transportation Fig 2 7 Conveyor Cutter extensions guarantee efficient work The material supply removal is carried out while the cutter is completing its jobs These extensions are available in different sizes either with or without auxiliary drive Fig 2 8 Cutter extension 2 6 5 Sheet feeder options Fully automatic sheet feeding 000003 06 11 2009 jmu Product description G3 Series Material handling options 2 6 6 Drip tray Catches cutting waste 2 10 000003 06 11 2009 jmu G3 Series Product description Technical description 2 7 Technical description 2 7 1 Complete machine The G3 cutter is a variable processing system for flexible and rigid materials with various tool systems Extension options are available to provide improved handling and for the adjustment of the system to special requirements or for processing specific materials 2 7 2 Schedule of work sequences CAD CAM Starting point CAD CAM data y Communication software e g Grafitroniks
104. l number already exists Collet is open The router cannot be started 000012 11 11 2009 jmu 6 21 Malfunctions G3 Series Error messages 0x0001B102 0x0001B203 0x0001B303 0x0001B403 0x0001B503 0x0001B603 0x0001B702 0x0001B801 Contact service Router still running collet cannot be opened Contact service The router converter is currently already being used by another tool Cause An attempt was made to use a router converter on two different tools at the same time Timeout when starting the router Cause The router could not reach its speed after being switched on Router overloaded Could not keep up the specified speed Cause The router has deviated too much from the target speed and has therefore been stopped Solution It may be the case that the routing speed has not been adjusted to the material Router overloaded The current in the converter is too high Cause The router is overloaded There is too much current flowing Solution It may be the case that the routing speed has not been adjusted to the material Different table reference point Cause A module was removed or added In this process it was determined that the same zero point can no longer be used Dummy module active Contact service Light barriers not active 6 22 000012 11 11 2009 jmu G3 Series Malfunctions 0x0001B903 0x0001BA03 0x0001BB04 0x0001BD03 0x0001BE03
105. lean the chipping protection brush Ensure that following precondition is fulfilled 1 The machine is in the maintenance position Cleaning the brush Fig 7 12 Clean the chipping protection brush gt Use a vacuum clean to extract chips and dust from the brushes 7 22 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs 7 7 10 Cleaning the feeding clamps feed guide rail Tools and materials K Lint free cloth X Spirit Ensure that following precondition is fulfilled 1 The machine is in the maintenance position Procedure gbo76 1 2 Fig 7 13 Cleaning the feeding clamps feed guide rail gt Clean the feeding clamps feed guide rail with a lint free rag and spirit 000001 10 11 2009 jmu 7 23 Cleaning and maintenance G3 Series Maintenance jobs 7 7 11 Draining the maintenance unit condensation water Tools and materials Container Ensure that following precondition is fulfilled 1 The machine is switched off Procedure Fig 7 14 Drain condensation water Disposal gt The condensation liquid from the water separator is contaminated with oil Therefore the liquid must be disposed of correctly according to the specific national regulations 10 0 2 0 Set the main switch of the maintenance unit to Off Hold a container under the drain Open the drain screw Allow the liquid to drip into
106. les and safety at work The operation of the machine is always subject to local regulations regarding sa fety at work and accident prevention Before the machine is put into operation Always check the safety equipment and protective covers If a hazardous situation occurs switch the machine from the ONLINE operating status to the STOPPED OFFLINE operating status Switching can be carried out by pressing the ONLINE button on the operating unit By pressing one or more direction keys emergency stop function You are not permitted to make unauthorised modifications and changes to the machine which might affect the system s safety Accessories or spare parts pro duced by other manufacturers may only be used with the machine with the writ ten approval of the manufacturer Only service personnel authorised by the manufacturer are permitted to install commission maintain and repair the machine Before carrying out any maintenance repair and modification work Switch the machine off using the on off switch and secure with a lock Prevent the machine being switched on inadvertently by removing the mains supply cables to the distribution box several mains connections Procedure in case of malfunctions In principle any troubleshooting work or inspection on the cutter is to be carried out only when it is switched off The following must never be by passed or rendered ineffective Light barriers and protective tri
107. leshooting Malfunctions Troubleshooting Attention Risk of injury due to incorrectly remedied faults Ensure that the error on the device is remedied correctly Contact you Z nd partner If cutter malfunctions occur and you need the help of our customer service department make a note of the following details Machine serial number The error message displayed on the operating unit A description of what circumstances the error occurred in Locate error Errors can be located both via the operating unit or ifthe operating unit is defective via the status and error display on the electronics unit Error display on the operating unit 1 O Failure O4Baa12103 4 light barrier has triggered _ 2 LB A Type 1 a ee n DE Fig 6 1 Error display on the operating unit 1 Error code 2 Error description 000012 11 11 2009 jmu Malfunctions G3 Series Locate error Error display on the status and error display example The error is displayed as a sequence No redundant figures of the error code will be shown in this display Example The error 0x0001D503 is abbreviated to the figures 1D503 If several errors occurred one after the other then these are combined together ina group The error which occurred first is displayed at the start of the group All other errors follow in order pozas 6 2 1 OBFOEO2L9A0I8090087 Fig 6 2 Error display on the status and error display
108. m the operating status STOPPED to ONLINE or use SHIFT on to switch to the operating status OFFLINE in order to reactivate the remote control 4 21 000010 09 11 2009 jmu Controls and operation G3 Series Operation 4 6 3 3 ONLINE 0 ON A green illuminated LED on the ONLINE key indicates that the operating status LINE ONLINE is active Commands are received and processed in this operating status gt ow must be pressed in order to activate the operating status ONLINE The displays shows the following message ONLINE CCOO Emd count ind Systemtechnik AG Use MM to switch from the operating status ONLINE to the operating status STOPPED or use on to change to the operating status OFFLINE 4 22 000010 09 11 2009 jmu G3 Series Controls and operation Operation 4 6 4 Moving the bar module manually Fig 4 14 Moving the bar module The module carriage can be moved using the travel keys in the operating status OFFLINE The assignment of keys corresponds to the direction of travel Pressing the SHIFT key at the same time will make the module carriage move faster Pressing travel keys in the X and Y direction at the same time will make the module carriage move diagonally If one or more travel keys are pressed in the operating status ONLINE then an emergency stop is triggered 4 23 000010 09 11 2009 jmu Controls and operation G3 Series Operation 4 6 5 Tool handling
109. mation Directions such as right left or forwards backwards are specified according to the operator s view of the machine during operation Fig 2 1 Directional information 1 Front 3 Left 2 Back 4 Right Y Yaxis X Xaxis Important information Important Refers to user tips and useful information which enhance the usability and prolong the service life of the machine and make the work significantly easier 000003 06 11 2009 jmu 2 1 Product description G3 Series Product identification 2 2 Product identification 2 2 1 Rating plate Important The rating plate is used to uniquely identify your machine 7 LUN consen CE 9 2 Product Cutter G3 3 TYPE L2500 Year 08 5 4 S N G300L250003 Fig 2 2 Position of rating plate 1 Manufacturer 5 Year of manufacture 2 Product category 6 CE marking 3 Device type 7 Manufacturer s address 4 Serial number 1 see chapter Introduction Standardisation CE marking Structure of the serial number seme G300L 250001 Serial number Description G3 Product OOL Bar length 25 Table length 0001 Consecutive device number 2 2 000003 06 11 2009 jmu G3 Series Product description Intended use 2 2 2 UL marking r 1 Unos LISTED UL 60950 E176661 2 Voltage 208 400 VAC 3ph 3 Current max 32 A Frequency 50 60 Hz Xx Fig 2 3 UL marking 1 UL mark
110. mod data Error in the parity test Contact service A mod offset is outside the tolerance Module 0s Offset 1s Contact service Err during data inspection The data cannot be used Contact service Err during Altera programming 000012 11 11 2009 jmu 6 29 Malfunctions G3 Series Error messages 0x00020304 0x00020403 0x00020503 0x00020603 0x00020704 0x00020803 0x00020903 0x00021104 0x00021203 0x00021403 Contact service Short circuit detected Index 0s Contact service Cam focus aid not locked PWM control over modulated The parameters must be adjusted Contact service Aux drive 0s not ready Contact service Comm to Y board interrupted Contact service Overload detected on OptionBoard String no 0s Driver no 1s Contact service Incompl HP GL comm Data may have been lost Command d2s is incorrect Fork light barrier err Axis 0s Status 1s Contact service Incorrect axis index Contact service Rev transport with aux drive blocked 6 30 000012 11 11 2009 jmu G3 Series Malfunctions 0x00021503 0x00021603 0x00021703 0x00021803 0x00021903 0x00021A03 0x00021B03 0x00021C03 0x00021E01 0x00022401 0x00022503 0x00022601 Error messages Trans file not a plotter update Contact service Trans file not a panel update Contact service Trans file not YM board update Co
111. n eak ee eee 7 2 Product description opie aaa ee Se E a a Se aa a A 1 2 1 General fase aa ate Ahi at a a he lar 1 2 2 Product identification ooooooooooooooooo ee 2 2 2 1 Rating plate 2 eee ee ee eee eee ee ee 2 232 2 ULMAN iss socia nda gate ge eee alate aaa aaa 3 2 3 Intended userid cele eet OG Ani noes dhs 3 2 4 Cutter 0Vernview in 2c 0 862d hades ey ewe bea nee 4 2 5 Modules toolS raaa a e a a ee nee es 5 2 5 4 A abe Re es de Ye ein el 4S even ti dod vate 5 225 2 A en ieee itera 22h a T T a boat atone tate Me tht ads teas tend 5 2 5 2 1 Tools for the UM 1 1 eee 6 2 5 35 IRMA stoeden iaa area dida 7 2 54 PUMA 7 2 6 Material handling options 0 0000 ee eee eee 8 260 17 Laser pointer vs dana ee eda he Be Ra eb Be E ada 8 2 6 2 ICC Camera ceci een faite Sen OE ee eed ne ee 8 2 6 3 Cutter with static work surface 2 2000 0c eee eee eee 8 2 6 4 Cutter with conveyor seira hrr rye EEEE ES REAP tees 9 2 6 5 Sheet feeder options nnana anaana cee eee 9 PRD I AE EE EE E Ns EO 10 2 7 Technical description n a anaa anan 11 2 7 1 Complete machine 000 0c cette 11 2 7 2 Schedule of work sequences 2 0000 e ee eee eee 11 2 7 3 Complete machine 0200 0c eee eee eee 12 2 7 4 Movement system 0 00 eee 13 2 7 5 Processing materials 0 0 cece eee 14 2 8 Technical information 00 000 c eee ee eee 15 2 8 1 Dime
112. nce at the back Vacuum mode Vacuum The material is held down by vacuum 5 24 000015 040 11 2009 jmu G3 Series Description of menu Description of menu Vacuum Stop The bar moves to the rear The feeder elements hold down the material Stand by position is approached Remove the cut material from the table The material feed is carried out once the mes sage has been confirmed 1 7 1 8 Feed comp Value for the compensation of the material dependent track during a feed cycle in mm 1 7 1 13 Ext Stop Feed stop which is triggered by an external signal Active The external signal is processed and the feed is stopped Inactive The external signal will not be processed any further 1 7 1 13 2 Confirmation Setting for what happens after a feed stop has been triggered manual as soon as the signal is no longer present this must be confirmed with OK automatic as soon as the signal is no longer present the feed is continued 1 7 1 14 Mat smooth Description to follow 1 7 1 14 1 Material smooth Description to follow 1 7 1 15 Start pos Setting the starting point of a feed The bar moves to the defined position and starts the feed 1 7 2 Manual feed Settings for the manual feed 1 7 2 1 Transport to the front 1 7 2 2 Important A transport to the front can only be executed when the feed system is correspondingly configured A feed is executed Starting point current position End point X
113. ng options The Z nd feed system allows the material to be processed to be transported on with a conveyor belt following a completed work process The conveyor belt is gripped and fed using two clamping elements while the material to be processed is fixed with feeding clamps a feed guide rail The arrangement and activation of the feeding clamps is determined based on the material to be processed If a feed guide rail is used then all feeding clamps are activated in fixed positions Depending on the size of the table or the material to be processed an auxiliary drive is used to support the bar during feeding The feed direction is defined via the position of the auxiliary drive Fig 4 28 Feed direction position of auxiliary drive 4 41 000010 09 11 2009 jmu Controls and operation G3 Series Feeding options 4 8 1 Feeding clamps gb 126 Fig 4 29 Feeding clamp 1 Feeding clamp 2 Compressed air on off 3 Screw for fixing the feeding clamps Setting the feeding clamps gt Loosen the screw for fixing the feeding clamp gt Position the feeding clamp pay attention to the hose length gt Tighten the screw for fixing the feeding clamp Activating deactivating feeding clamps gt Turn the screw clockwise in order to deactivate the vacuum element gt Turn the screw anti clockwise roughly three rotations in or
114. ng the extraction of different materials Obtain information about the risk of explosion when processing the type of ma terial that you are using e If necessary adjust the extraction to the required regulations Fire classes Refer to the following table to find out which type of fire extinguisher is used for each fire class A Solid materials mainly organic in nature e g wood paper textiles etc B Liquid and liquefiable substances e g petrol oils greases paints etc C Combustible gases methane propane etc 3 24 000011 08 11 2009 jmu G3 Series Safety Ai Aa 3 22 3 23 Danger caused by laser beam laser pointer In the event of a fire e Switch off the machine emergency stop switch e Assess the situation If the situation is dangerous leave the area immediately and call the fire brigade Only try to extinguish the fire if your personal safety is not at risk Remove a suitable fire extinguisher A B C from its bracket and prepare it for use e Locate the source of the fire Attack the fire with repeated short bursts from the extinguisher Always spray the extinguishing agent into the source of the fire In other words always aim at the burning material and not at the flames e After using the fire extinguisher do not return it to its usual place but have it re filled immediately Observe the following safety rules and countermeasures Find out the number of locat
115. nitialisation is started via the F1 key Stop A stop is triggered by pressing the movement keys in the ONLINE operating status In this process all cutter movements are stopped and the OFFLINE operating status is activated Feeding clamps Feeding clamps fix the processing material during a feed movement on the conveyor belt Tool Tools are used in modules There are tools available for processing many common materials e g EOT POT DRT etc 14 2 000014 05 06 2009 jmu
116. ns 3 Air pressure setting for various modules vacuum elements P2 The maintenance unit is preset and adjusted Check the air pressure setting at regular intervals The settings can be found in the chapter Product description Specifications 000010 09 11 2009 jmu Controls and operation G3 Series Controls 4 3 4 Interfaces The machine has interfaces for data exchange These are attached to the electronics unit gb101_2 E i sE SNLVLS 1SOH 39143A NVI WOOD oa w WOO o Fig 4 10 Interfaces 1 LAN 4 Status and error display 2 Not used 5 COM 1 3 USB Host 6 COM 2 4 10 000010 09 11 2009 jmu G3 Series Controls and operation 4 4 4 4 1 Menu navigation Menu navigation Menus and functions Navigation The cutter has a large number of functions The current menu number and the current menu are displayed in the header 21 Reference point settings 1 Ret point 1 options Fig 4 11 Current menu number menu Graphic layout Symbol Description Menu Blocked menu user level Value entry command Oveptl Display of a value Navigation in the menu gt Use the navigation keys A VW to scroll through the menu and use gt to select a submenu a function e g Tools gt To return to the previous menu level press the navigation key q Press ESC to retu
117. ns Width B4 Width B2 Height D x E in B x C in in in Work surface A in M 1600 52 x 63 80 9 x 98 9 M 2500 52 x 98 80 9 x 134 3 L 2500 71x98 99 4 x 134 3 L 3200 71x 126 99 4 x 161 9 XL 1600 89 x 63 117 9 x 98 9 11 8 24 6 32 7 XL 3200 89 x 126 117 9 x 161 9 2XL 1600 108 x 63 136 4 x 98 9 2XL 3200 108 x 126 136 4 x 161 9 3XL 1600 126 5 x 63 154 9 x 98 9 3XL 3200 126 5 x 126 1554 9 x 161 9 000003 06 11 2009 jmu Product description G3 Series Technical information Type Static material clea Material clearance Material clea rance width 1 D in width with CV D in rance thickness tin M 1600 63 4 52 4 M 2500 63 4 52 4 L 2500 81 9 70 9 L 3200 81 9 70 9 XL 1600 100 4 89 4 2 4 1 2 XL 3200 100 4 89 4 2XL 1600 118 9 107 9 2XL 3200 118 9 107 9 3XL 1600 137 4 126 4 3XL 3200 137 4 1226 4 1 The work surface and material clearance width are dependent on the tool and the module 2 Two versions are available max Type Weight Ibs floor load lbs in M 1600 1463 M 2500 1837 L 2500 2129 L 3200 2446 XL 1600 1954 450 XL 3200 2823 2XL 1600 2140 2XL 3200 3110 3XL 1600 2457 3XL 3200 3540 Type Max weight proces Max weight proces sing material lbs sing material lbs in M 1600 M 2500 750 L 2500 992 L 3200 1278 XL 1600 816 121 XL 3200 1631 2XL 1600 970 2XL 3200 1940 3XL 1600 11
118. nsions and weights 000 cee eee 15 2 8 1 1 BaSIC DEVICE 45 53 bos ala laa BAW Aa Ria ee 15 2 8 1 2 Cutter extensio 1 eee 17 2 8 2 Electrical connection power consumption 2055 18 2 8 3 Environmental conditions 2 00 eee 19 0 1 000017 03 06 2009 jmu G3 Series 2 8 4 2 8 5 2 8 6 2 8 7 2 8 8 3 1 3 2 3 3 3 4 3 4 1 3 4 2 3 5 3 6 3 7 3 8 3 9 3 9 1 3 9 2 3 9 3 3 10 3 11 3 11 1 3 11 2 3 11 3 3 12 3 12 1 3 12 2 3 12 3 3 12 4 3 13 3 14 3 14 1 3 14 2 3 14 3 3 15 3 16 3 17 3 18 3 19 3 20 3 21 3 22 3 23 3 24 3 25 4 1 4 2 Basic device compressed air 0 0 eee ees 19 CONTAINS e tal de o ad 19 PEO MANCO barra Rae dat aa Dey 4 ade ae AA 20 EMISSIONS a Aoao cd et tate gd ot an case Sete dn ted lei ce aes je dee 21 FCC approval accuse hea GW Ph eka he a eae eS 21 A cant net eee Os RGU ee See ee 1 General hie ssh eaten eh ond Cale lta ake A Jaded ties 1 Proper USE cimil a eee ee BE eS 2 Examples of improper use ooo 2 Hazard warnings important instructions 22222005 3 Explanation of the hazard warning 0 00 eee eee eee 3 Structure of the hazard warnings 0 0c eee eee eee 4 Areas of responsibility 0 2 00 ee 5 Personnel requirements 0 0200 eee eee teens 5 Rules and safety at work 0 0 0 00 eae 6 Procedure in case of malfunctions 0 0000 e eee eee 6 Danger areas eii
119. ntact service Trans file not a cam update Contact service Trans file not a mod board update Contact service New mod board FW does not match installed mod type installed 2s Contact service Trans Altera file not recognised Contact service No data for update Contact service OptionBoard Str1A not available Take up unwind units therefore deactivated Contact service Error during camera communication Check connection cable In the case of PUM a cylinder locks in the lower position Contact Service Changes to the Ethernet parameters will only become effective after the cutter is re started 000012 11 11 2009 jmu 6 31 Malfunctions G3 Series Error messages 0x00022703 0x00022803 0x00022903 0x00022A03 0x00022B03 0x00022C03 0x00022D01 0x00022E03 0x00022F02 0x00023003 0x00023203 0x00023301 The received HPGL command does not correspond to the syntax 2s Contact Service Universal board Typing error Contact Service Universal board Read error Contact Service In the case of PUM no cylinder has arrived in the lower position Contact Service Synchronisation problem on the Universal Board SPI Contact Service An error occurred on the universal board Contact Service The start point is outside of the value range and will therefore be deactivated Contact Service Negative feeds cannot occur with the universal unwinding unit
120. ntrol unit Inserting and connecting a tool Fig 4 21 Insert tool 4 31 Controls and operation G3 Series Operation 4 6 7 1 Bayonet catch 4 Positioning spindle 2 Module lock 5 Positioning bracket 3 Connector socket Important The tool holder and a holding fixture are each marked with a red dot The tool is in the correct position when the dots are aligned gt Move the module to the lower right hand corner gt Use to switch to the STOPPED operating status Insert the selected tool into the module holder Ensure that the red point on the module is located above the module lock Lower the shaft of the tool into the module opening until it stops gt Press the module lock and latch the bayonet catch gt Turn the tool in a clockwise direction until the first notch on the positioning bracket engages with the positioning spindle gt Connect the tool to the connector socket Connecting driven tools allocating port Driven tools e g EOT DRT POT require an energy supply electrical pneumatic This energy supply is controlled by the cutter control unit Electrically driven tools are inserted into the intended port on the connector control of the laser pointer ICC camera Pneumatically driven tools are already internally connected to the compressed air supply A port is allocated to each
121. ocessing other materials on the other hand As standard three modules can be fastened onto the module carriage Instructions on the operation of your module can be found in the chapter Modules Tool inserts Tools Z nd offers tools for processing the most wide ranging materials A selection of important tool inserts can be found under the corresponding module On the Z nd homepage www zund com you can find all the current tool inserts or contact your Z nd partner for detailed information Instructions on the operation of your tool module can be found in the chapter Modules Tools Tangentially controlled high performance module for the following tool inserts POT EOT DRT e Various insert sleeves and tool holders 000003 06 11 2009 jmu Product description G3 Series Modules tools 2 5 2 1 Tools for the UM CC ee POT Pneumatic oscillating tool for thick or tough materials such as foam filling materials thick leather upholstery fabrics etc EOT Electrical oscillating tool for cutting soft to average toughness materials DRT Driven tool for rotating knives for cutting textiles fibrous materials such as Kevlar carbon WL O VCT Cutting tool for producing V cuts UCT Cutting tool which can be used universally KCT Cutting tool for foils with and without mount material UDT Marking tool 2 6 0
122. ode Solution Switch the system to the operating status OFFLINE or ONLINE and carry out the instruction again Light barrier triggered LB 0s Type 1s Cause A light barrier has triggered either because it is defective or because its beam of light was interrupted In the first parameter the error states which light barrier it is related to and in the second it states what kind of error it is LB 0 Front light barrier LB 1 Back light barrier LB 2 Left hand reflex light barrier LB 3 Right hand reflex light barrier Type 1 Beam of light interrupted Type 2 Light barrier probably defective Important Be aware that it is not guaranteed that the connection of the front and back light barriers have been swapped Solution Remove object from the beam of light e Check that the light barrier is correctly connected e Check for cable interrupt e Replace light barrier This function or this parameter is not available for this module Change the module Contact service This function is not permitted from this task Command 0s Caller index 1s Contact service This initialisation mode is not supported Contact service 000012 11 11 2009 jmu Malfunctions G3 Series Error messages 0x00012C04 0x00012F02 0x00013002 0x00013102 0x00013202 0x00013303 0x00013704 0x00013803 0x00013B01 0x00014103 Axis inspection err Axis 0s Error 1s Contact service
123. of danger cannot be localised due to the lack of safety signs e Replace missing or illegible safety signs as per Fig 3 5 The operator is responsible for replacing missing illegible safety signs on the machine The appropriate safety signs can be requested from your service partner 3 11 2 The signal words DANGER indicates an imminently hazardous situation which if not avoided will A DANGER i E result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may 3 11 3 Position of the safety signs Crush hazard Keep hands clear of moving parts PR PS A Eye protection X Moving parts can dy required LA crush and cut 6 E Za Keep hands out of moving mechanism Savety gloves required Laser radiation LH Do not stare into Ca beam Laser class II A 7 Hazardous power inside Disconnect all power supplies before servicing Cr Service by trained personnel only Hazardous power inside Y IN Service by trained a C personnel only 000011 08 11 2009 jmu Safety G3 Series
124. oled down Communication between the panel and MC interrupted Contact service Unknown module position Contact service This tool is still inserted in another module Contact service Incorrect logger parameter Index 0s Contact service Clipping area is too small Cause The clipping window was defined to be too small It is not possible to carry out a calculation Errors are still present Contact service Command Os not carried out Contact service Error during the system start up Restart the cutter Error no 0s Error index 1s Contact service No travel movement is possible with the current module Cause A virtual module is selected It is not possible to move the axes with this module The virtual module is selected if a select pen is set on a module which is not available on the active head 000012 11 11 2009 jmu Malfunctions G3 Series Error messages 0x00019C03 0x00019D02 0x00019E03 0x00019F02 0x0001A202 0x0001A303 0x0001A403 0x0001A603 Solution Select valid module Terminator characters not permitted Contact service Unknown machine ID Contact service Flash already occupied Contact service Error in a S19 row Contact service Feeding clamp not configured Cause The feeding clamp is not installed has not been activated Solution Activate the feeding clamp in the feeding clamps menu Feed initialisation error Cau
125. on of menu 1 1 1 Tool pos 1 1 2 gb125 N Fig 5 2 Tool slot tool assignment e g Module 2 tool 1 1 Module 2 UM tool slot 2 Tool pos 1 2 Oscillating tool tool 1 Each module consists of up to four tools e g PUM The first figure of the menu entry shows the tool slot of the module the second figure shows the tool position The menu entries of the tools 11 14 21 24 31 34 41 44 are identical The allocations and settings of the tools are carried out in the following submenus 000015 040 11 2009 jmu 5 3 Description of menu G3 Series Description of menu 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 2 2 1 1 1 2 3 1 1 1 2 4 1 1 1 2 5 1 1 1 2 6 Select tool Assign the tool that is used in the module For the attachment selection of a new tool see chapter Controls and operation Tool handling Initialisation Setting of the tool working height Further tool specific information relating to the initialisation can be found in the operating manual of the respective tool type Define Z init pos Determining the Z position as the initialisation position for the current tool Auto init Automatic initialisation with AKI gt Position auto init tool on the work surface gt Start function The selected tool moves via the initialisation tool and starts the initialisation procedure Y The value that is determined is saved for the specific tool Up Z pos Value for setting the tool
126. on of the suction unit during process ing Offset Switch Offse i 1 1 3 5 3 on off Tool delay settings Setting of the tool specific delay times Before down delay Delay before lowering the tool After down delay Delay after lowering the tool After down action delay Delay time for tools which carry out an action after the lowering E g passepartout tool 5 10 000015 040 11 2009 jmu G3 Series Description of menu Description of menu 1 1 1 3 6 4 After down delay Delay before lifting the tool 1 1 1 3 6 5 After up delay Delay after lifting the tool 1 1 1 3 6 6 Before up action delay Delay time before lifting when the tool carries out an additional action E g passepartout tool 1 1 1 3 6 7 Up Impulse delay Display of the delay before raising the tool PUM 1 1 1 3 6 8 Up Impulse length Display of the impulse duration for lifting the tool PUM 1 1 1 4 Correction Description to follow 1 1 1 4 1 Correction Activate deactivate knife connection accuracy 1 1 1 4 2 Correct X Correction value for the compensation of the tool tolerance optimisation of the infeed angle Refer to 7esf cuf 1 1 4 4 for the determination of the correction value 1 1 1 4 3 Correct Y Correction value for the compensation of the tool tolerance optimisation of the infeed angle Refer to 7est cuf 1 1 4 4 for the determination of the correction value 1 1 1 4 4 Test cut Correction values general Important The penetration point and or the cut
127. on on the structure of the individual chapters The numbers of pages and certain large graphics are prefixed with the number of the relevant chapter Page number 2 10 for example means the tenth page of chapter 2 Product description 1 2 000009 06 11 2009 jmu G3 Series Introduction Using the documentation 1 2 2 Symbols Illustration Close fix tighten in lt Open release loosen out Higher lt Lower Text structuring D gt Task Steps to perform Y Result Outcome of the tasks performed Q Prerequisites for performing a task X List of tools Optional accessories There are a number of optional accessories available for the machine Any description relating to an optional accessory is identified in the operating manual by the symbol 000009 06 11 2009 jmu Introduction G3 Series Points to note when reading this operating manual 1 3 1 4 Points to note when reading this operating manual Text references Chapter headings are numbered consecutively with the first figure corresponding to the chapter number Where reference is made to sections outside the current chapter note the first figure and turn to the corresponding chapter which contains the cited section See chapter 2 4 Overview of the machine for example leads to chapter 2 Product description which contains section 4 Overview of the machine Sketches and schematic representations These ar
128. ool gt Inserting the module gt Inserting tool gt Choose Select toof 1 1 1 in the menu gt Use p gt to change to the 7oo menu All tools already assigned to this module are listed Select the required tool Save tool specific cutter settings gt Use ESC to change to the main menu The tool specific settings that have been made are automatically saved 4 26 000010 09 11 2009 jmu G3 Series Controls and operation Operation 4 6 6 Modules tools 4 6 6 1 General gb084 Fig 4 17 Module carriage module tool blade router etc Module e g RM UM Tool e g 1000 W motor spindle oscillating tool Module carriage e g 3 way Router blade etc A ON 4 27 000010 09 11 2009 jmu Controls and operation G3 Series Operation 4 6 6 2 Inserting replacing the module Setting the position of the module carriage for changing the module can be set at operator user level or higher Fig 4 18 Example module carriage position for changing the module 1 Example module carriage position 1 for changing standard modules 2 Example module carriage position 2 for changing UM You can choose any two positions for changing the module o 5 gt Select 1 5 7 Module change pos Select 1 5 7 2 Position 7 or 1 5 7 5Position 2 Use the module carriage to move to the required position and confirm using OK In menu 1 5 7 1 Position select the position in which t
129. ool is lowered Adjusting value 1 1000 mm s Lift Z Speed when raising the tool Lower Z Speed when lowering the tool Accel settings Setting of the tool acceleration The maximum possible acceleration depends on the following factors e Table size Module carriage weight Up X amp Y Acceleration of the tool in the X Y direction when the tool is raised Setting range Levels 1 4 12 5 25 50 100 Down X amp Y Acceleration of the tool in the X Y direction of the lowered tool Bb 0O0ON Setting range Levels 1 4 1 12 5 25 3 50 000015 040 11 2009 jmu 5 7 Description of menu G3 Series Description of menu 1 1 1 3 3 3 1 1 1 3 3 4 1 1 1 3 4 1 1 1 3 4 5 1 1 1 3 4 6 1134 7 1 1 1 3 4 7 1 1 1 1 3 4 7 2 1 1 1 3 4 7 3 1 1 1 3 4 7 4 4 100 Lift Z Acceleration of the Z axis when raising the tool The setting is done in mm s Lower Z Acceleration of the Z axis when lowering the tool The setting is done in mm s Z axis settings Menu for setting the Z axis parameters Down Z pos Setting of the cutting depth the tool position when the tool is lowered This position should only be set as deep as is necessary in order to avoid damage to the cutting base Max Z down Limitation of the Down Z pos for the protection of the work surface This value specifies the maximum possible cutting depth This
130. oordinates of position 2 000015 040 11 2009 jmu 5 21 Description of menu G3 Series Description of menu 1 6 1 6 1 1 6 1 1 1 6 1 1 1 1 6 1 1 1 1 6 1 1 2 1 6 1 1 2 1 6 1 1 3 1 6 1 2 1 6 1 3 Table General table settings Park options The parking function is linked to the HP GL command PK in the ONLINE operating status If this command is triggered the module carriage moves to the park position The keys on the operating unit other than keys 1 3 are blocked Using Exit park1 6 1 1 3 the module carriage moves to the initialisation point and the ONLINE operating status is activated The park position settings of the module carriage and the options during the park function are carried out in this menu The park command positions the module carriage at a particular point on the work surface in order to be able to carry out settings work or loading and unloading without disruption If the park function is active only functions from the submenu Park options 1 6 1 1 can be performed Park pump functions Functions while the module carriage is in park position Vacuum off Vacuum is switched on Use to switch the vacuum off Vacuum on Vacuum is switched off Use to switch the vacuum on Blow abc Suction function is active Use 2 to switch to blowing Suction Blowing function is active Use 2 to switch to suction Exit park Important The module carriage automatically
131. op switch a O Check all safety devices correct functioning of light barriers protective trip switch Table complete O Check all screw connections and tighten according to requirements if necessary O Check levelling O Check feed system O Check cabling wiring and cable routing for signs of wear Vacuum plate O Conveyor Check levelling and adjust if required replacement O Check the correct functioning of the vacuum zone control Bar O Check perpendicularity and align if required O Check length compensation and adjust if required Feeding options a O Clean rubber cushions needle cushions of the feed elements 7 7 10 A O Clean feed guide rail 7 7 10 O Clean and oil feeding clamp piston rods X axis drive E O x Clean and oil guide rails guide carriage 7 7 5 7 7 6 O Check tension of toothed steel belt and readjust if necessary O Check alignment of toothed steel belt and readjust if necessary O Check pivot bearing tension adjust if necessary O Clean and lubricate the gears O Clean the drive belts O Clean the drive and guide rollers Aa O Clean the chipping protection brush 7 7 9 Y axis drive E 0 Clean and oil the guide rails 7 7 7 7 6 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Steps for maintenance Maintenance inspection during operating hours Work to be carried out a By personnel By authorised
132. or Light barrier defective 000015 040 11 2009 jmu 5 23 Description of menu G3 Series Description of menu 1 6 2 5 3 1 6 2 5 4 1 7 1 7 1 1 7 1 1 1 7 1 2 1 7 1 3 1 7 1 4 1 7 2 4 1 8 1 5 Free The light barrier is not interrupted Interrupted The light barrier is interrupted Reflex LB left Testing the front light barrier Error Light barrier defective Free The light barrier is not interrupted Interrupted The light barrier is interrupted Reflex LB right Testing the front light barrier Error Light barrier defective Free The light barrier is not interrupted Interrupted The light barrier is interrupted Feeding options Setting of the feeding system Feeding options Feed settings Start Execute feed Length Define the feed length Speed Enter speed of the page feed mm s Acceleration settings Select feed acceleration levels 1 12 Select acceleration for specific materials Level 1 slow acceleration Level6 medium acceleration Level 12 fast acceleration Feeding mode The feeding mode function offers three different feeding and removal variations Normal The material is fed in from the back and removed from the front Bidirect 1 The material is fed and removed on the same side Bidirect 2 The material is fed and removed on the same side This process is car ried out alternately once at the front and o
133. p switches on the bar Monitoring sensors Safety and control switches in the machine If malfunctions cannot be remedied by the operators using simple measures then the responsible service station must be informed 3 6 000011 08 11 2009 jmu G3 Series Safety Danger areas 3 9 Danger areas 3 9 1 General danger area Fig 3 1 General danger area 1 Danger area 000011 08 11 2009 jmu Safety G3 Series Danger areas A 3 9 2 Danger area on the module carriage Attention Risk of injury on the module carriage The danger area on the module carriage is not secured using safety devices e Do not reach into the danger area during the manual initialisation Secure the danger area on the module carriage using the slot protective plates N Fig 3 2 Danger area on the module carriage 1 Danger area 2 Slot protective plate Place a slot protective plate on each module slot on which no module is installed 3 8 000011 08 11 2009 jmu G3 Series Safety 3 9 3 Danger areas Danger area during the installation Attention Risk of injury during the manual initialisation of the tool The safety devices are not active during the manual initialisation Do not reach into the danger area during the manual initialisation e Use the automatic initialisation function for the initialisation gb269 Fig 3 3 Danger area during the installation 1 Danger ar
134. please contact your customer service representative to arrange proper conservation of the machine or to put the machine back into operation Work instructions When working on the machine you must observe the safety measures described in the Safety chapter e Absolute cleanliness must be maintained at all times Replace damaged parts immediately with new original spare parts Tool heads tools and options Maintenance intervals instructions on maintenance and cleaning for modules and options can be found in the corresponding operating manual 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Safe maintenance of the machine 7 2 Safe maintenance of the machine General safety instructions Servicing and repair work must be carried out by trained specialist personnel For periodic checks inspections you must comply with the mandatory intervals or the intervals specified in the instruction manual Equipment appropriate to the task must be available in order to carry out maintenance tasks The maintenance schedule specifies precisely who is to carry out which jobs The jobs listed as daily weekly tasks may be carried out by operating personnel after appropriate training You must ensure that spare parts meet the technical requirements laid down by the manufacturer Original spare parts are always guaranteed to do so The wearing of protective clothing see Personal protective equipment clothing in S
135. position when the tool is raised procedure To increase cutter efficiency this position should only be set as high as is necessary Test cut Carry out a quadratic test cut 20 mm x 20 mm The zero point of the square is the lower right hand corner The test cut is carried out in the current tool position Procedure Place the material to be processed on the working surface Select the function gt Switch on vacuum VAC 2 Use the travel keys to position the tool over the current material to be processed Choose OK to confirm gt Check the test cut If necessary redefine the the zero point on the Z axis or correct it using the Z Offset function Z Offset Value for adjusting the processing depth by 1 5 mm The Z offset function moves the Down Z pos by the value that is entered Init height Define the height of the suction unit during processing Procedure 000015 040 11 2009 jmu G3 Series Description of menu 1 1 1 3 1 1 1 3 1 1 1 1 3 1 1 1 1 1 3 1 1 1 1 1 3 1 1 1 1 1 3 1 2 1 1 1 3 1 3 1 1 1 3 1 4 1 1 1 3 1 5 Description of menu Bea amp e1 re ghi JK oag 7 lt gt A Fig 5 3 Init height gt Select function gt Use the travel keys to move to the suction height and confirm the dialogue using OK Tool setup Tool specific settings These settings are saved for the assigned tool Setup Tool specific setting
136. ption of menu Display of the window area The limits of the activated window are shutdown Top left X X coordinate of the upper left hand corner of the window area Top left Y Y coordinate of the upper left hand corner of the window area Bottom right X X coordinate of the lower right hand corner of the window area Bottom right Y Y coordinate of the lower right hand corner of the window area Window 2 options Define window 2 Surface compens A defined area of the work surface is scanned in a grid This procedure ensures that uneven areas are compensated for during processing The scanning is done with the suction unit of the RM A Surface compensation is only available for the RM A A detailed description can be found in the operating manual for the RM A Start measurement The measurement is performed in stages 1 Define the area in which the measurement should be made Move to the two ou termost points of the area using the active pointer laser pointer active module 2 Define the grid Set the distance between the measuring points min 30 mm max 1200 mm 3 Carry out the measurement Surface compens Surface compensation On Off Show area The active pointer active module or laser pointer leaves the defined area Remeasure the area Remeasure the area which has already been defined Area Show whether or not an area is defined active an area is defined inactive no area is defined Grid Show the dis
137. r belt Stapler with suitable staples 6 mm Applicator gun 2 component adhesive cartridge Spatula Masking tape 2 cm wide Gaffer tape XRRRKR RRR Industrial scissors Ensure that following precondition is fulfilled Li The machine is switched off 7 7 13 1 Removing the conveyor belt Undoing the tensioning screws Fig 7 17 Undoing the tensioning screws 1 Left right tensioning screws Undo the tensioning screws on both sides 7 27 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs Removing the conveyor belt Cut the conveyor belt using scissors and remove it Dispose of the conveyor belt correctly 7 7 13 2 Removing the covers ZS Fig 7 18 Removing the covers Lift the covers 1 x front 1 x rear and remove from the guide 7 28 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs 7 7 13 3 Fitting a conveyor belt Important Conveyor belt installation is dependent on the direction of movement Pay attention to the marks on the belt and ensure that the belt is fitted correctly Determining conveyor direction 2 Fig 7 19 Determining conveyor direction 1 Conveyor belt roll 2 Conveyor direction Unroll the conveyor belt as shown in Fig 7 19 A gt stamp is located on the front upper side The points in the feed direction Feeding through the conveyor belt G3 Cutter
138. rm a test cut and recalculate the correction value if necessary Y The axes alignment process is complete when the cuts lie on the same line tolerance 0 1 mm Where necessary check this using a magnifying glass 000015 040 11 2009 jmu Description of menu G3 Series Description of menu Correct X When a centre alignment is carried out the cuts are moved towards the coordinate system centre until the cut and the coordinate system are congruent Measure and calculate distance b mm in penetration point line 1 to penetration point line 2 of the parallel cuts to the X axis as follows gt Start the Test cufi 1 1 4 4 function Option 1 The distance between the penetration points is greater than the distance between the ends of the cuts X1 X2 b 2 Option 2 The distance between the penetration points is smaller than the distance between the ends of the cuts X1 X2 b 2 Result The penetration points are positioned precisely in the centre b Distance in mm in X1 calculated value X2 current value from Correct X1 1 1 4 2 gt Enter the calculated value X1 in the Correct X 1 1 1 4 2 field Perform a test cut and recalculate the correction value if necessary Y The centre alignment is complete when both penetration points are precisely in the centre tolerance 0 1 mm Where necessary check this using a magnifying glass 1 1 1 4 5 Test tool rotation T
139. rn back to the main menu Direct selection of menus Each menu and each function is allocated a unique menu number It is possible to change between menus by entering the menu number Two figure menu numbers 10 11 etc are displayed in lower positions Commands functions Commands are carried out immediately after the entry gt Use the navigation keys A V to mark the required command and select using gt gt The command can be triggered directly via the menu number In order to do this enter the menu number on the control panel An exception to this rule is made for safety relevant commands e g automatic moving These can be confirmed using OK or cancelled using ESC 000010 09 11 2009 jmu Controls and operation G3 Series Menu navigation Value entry Ifa flashing cursor appears on the display below a number then a number input is required gt Enter the required value using the numerical keys gt Check the value and confirm using OK or cancel the entry using ESC Select Select tool O Mo tool 0 a UOT 1 o UOT 2 a UCT 41 Mew Delete Ok Esc gt Use the navigation keys A V to select an entry from the list gt Confirm using OK or cancel using ESC Default settings factory setting Up Z pos 16 66 mm PLS Deft Ok Esc Default settings are available for many functions values gt Select function gt Use Def to reset the value to the factory setting Min max
140. rrent job Reference point settings Two reference points start points can be defined on the work surface The reference point automatically determined by the machine during start up is deactivated following the activation of a reference point See chapter Controls and operation Reference point Ref point 1 options Set reference point 1 Move to reference Position active tool at reference point 1 Clear reference Clear reference Define reference Use the travel keys to move to the required position and confirm using OK Current X reference Display of the X coordinates of the reference point Current Y reference Display of the Y coordinates of the reference point Scale settings Enlarge or reduce a job by the entered factor X scale Factor X direction Y scale Zoom factor Y direction Placement settings Settings for positioning a job Rotation options Menu item has no content Adjust angle Menu item has no content Define rotation centre Menu item has no content Angle Menu item has no content Centre X rotation 000015 040 11 2009 jmu 5 31 Description of menu G3 Series Description of menu 2 4 1 6 2 4 2 2 4 2 1 2 4 2 2 2 5 2 5 1 2 5 2 2 6 2 6 1 2 6 1 1 2 6 1 2 2 6 1 3 2 6 1 4 Menu item has no content Centre Y rotation Menu item has no content Offset Move output in X Y direction X Offset Value by which the output is mov
141. s Contact Service T axis of the PUM is blocked 000012 11 11 2009 jmu 6 33 Malfunctions G3 Series Error messages 0x00024403 0x00024504 0x00024602 0x00024702 0x00024803 0x00024901 0x00024A02 0x00024B03 0x00024C03 0x00024D03 0x00024E03 Contact Service Pilz emergency cables are crossed Serious system error 1s 2s Please insert the MAM marking module into another slot unless the module is being updated The zero mark buffer has probably not been set correctly Contact Service Tool not inserted in conn 0s Error in initialisation of axis 0s Cache size for protected parameters exceeded Contact Service Ext material handling 0s not ready Contact Service Feed with suctioned material transport is not permitted Contact Service Despite repeated attempts the axis 0s could not be correctly initialised Contact Service The gap between at least two measuring points was outside the tolerance The measurements that are too low have been ignored 6 34 000012 11 11 2009 jmu G3 Series Malfunctions 0x00024F03 0x00025003 0x00025101 0x00025201 0x00025303 0x00025403 0x00025503 0x00025603 0x00025703 0x00025803 0x00025903 Error messages The correction value measured is too high A local elevation is outside the tolerance The measurement was cancelled OptionBoard Str1A not available The Fusion Board Feeder
142. s Tool connector Determining the connection of the tool Converter If two converters RM are available either converter 1 or converter 2 can be assigned Select converter 1 or 2 as the converter for this module Infeed angle Setting of the infeed angle for the VCT The selection of the infeed angle ensures that the blade automatically penetrates into the material at the correct angle The penetration point can be optimised using the functions X correction Y correction see section 2 10 X Y correction The X Y correction value depends on the infeed angle and is selected automatically Switch off time The tool switches off after a specified period of time without the receipt of data Rpm Setting of the motor spindle speed The adjustable speed is dependent on the spin dle type After on delay Waiting time until the tool has reached the nominal frequency After off delay 000015 040 11 2009 jmu Description of menu G3 Series Description of menu 1 1 1 3 1 6 1 1 1 3 1 7 1 1 1 3 1 8 1 1 1 3 1 9 Waiting time until the tool stands still Continuous Path Continuous path switched on The speed is the same in all directions The speed can be calculated using the setting value from Down X amp Y 1 1 1 3 2 2 Continuous path switched off The speed is calculated from the set axis speed in X and Y direction Start with man Init Setting of whether the motor spindle is switched on or off during t
143. s Operating pressure 0 6 0 8 MPa Min air flow 5 3 gal min Setting pressure regulator maintenance unit 0 6 MPa P2 Additional specifications and requirements can be found in the chapters Modules tools options material handling Control unit Execution 4 axis control X Y T Z Variable prognostic vector processing Software Command set HP GL extended Data format ASCII Interface RS 232C V24 600 38200 Baud 1 MB input buffer with replot function 000003 06 11 2009 jmu 2 19 Product description G3 Series Technical information 2 8 6 Performance Precision Value Units Resolution of measuring system 0 0002 lin Positioning accuracy at a constant temperature 0 004 jin Repeat accuracy 0 0012 in Evenness of the table 0 008 lin Cutting performance Value Units Speed in the vector direction 0 04 55 67 in s Max acceleration in the vector direction 358 27 in s Max permitted printing force of the printhead 200 N creasing 1 depending on the module equipment and cutter size 2 20 000003 06 11 2009 jmu G3 Series Product description 2 8 7 2 8 8 Technical information Emissions Noise Continuous sound pressure level of the cutter lt 75 dB A Depending on the tool system and materials to be processed if the limit value of
144. s with continuously adjustable vacuum range 5 28 000015 040 11 2009 jmu G3 Series Description of menu Description of menu 1 8 3 2 Define vacuum range Fig 5 16 Define vacuum range position the active tool above the left edge of the material to be processed Choose OK to confirm Y The vacuum range has been defined 1 8 3 3 Active zones The active tool moves to the end of the active vacuum range or to the last active vac uum zone 1 8 3 5 Active zones 5 29 000015 040 11 2009 jmu Description of menu G3 Series Description of menu Fig 5 17 Vacuum zones e g L 2500 Status display of how many vacuum zones are currently active 1 8 4 Switch valve options Settings for controlling the switch valve 1 8 4 1 Switch valve options Activating deactivating switch valve 1 8 4 4 Pulse length Duration of the blowing 1 9 Init tool options Setting and functions for automatic initialisation 1 9 1 Init tool options Activate deactivate init tool 1 9 2 Start Ensure that following precondition is fulfilled LI the AKI is positioned on the work surface The selected tool moves via the AKI and starts the initialisation procedure 5 30 000015 040 11 2009 jmu G3 Series Description of menu 2 1 2 1 1 1 2 1 1 2 2 1 1 3 2 1 1 4 2 1 1 5 2 2 1 2 2 2 2 4 2 4 1 2 4 1 1 2 4 1 3 2 4 1 4 2 4 1 5 Description of menu Job setup Settings relating to the cu
145. s you with the controls guides you through the operational procedures and describes the following operating steps Daily commissioning Operation of the main components Detailed information on the operation of the machine Safe switching off of the machine Safe working practices Danger Operating errors or negligence can put human lives at risk as well as causing serious damage to the machine The machine is fitted with safety devices to minimise risk However these safety devices cannot guard against damage as a result of operating errors or negligent working practices Observe the safety requirements from the chapter Safety and the situational safety requirements of the appropriate working step As the operator you are responsible for the safe use of the machine You must observe the following The safety instructions given in Safety The information contained in this chapter bearing in mind the training provided by the manufacturer or retailer 000010 09 11 2009 jmu Controls and operation G3 Series Controls 4 3 4 3 1 Controls Control panel Fig 4 1 Control panel 1 Switch unit 2 Emergency stop switches 3 Operating unit 4 2 000010 09 11 2009 jmu G3 Series Controls and operation Controls 4 3 1 1 Operating unit gb260 Fig 4 2 Operating unit 1 Display 7 STOPkey 2 Soft keys 8 ONLINE key 3 N
146. se An error occurred during the initialisation of the page feed process Solution Check paging configuration No material Contact service Incorrect number of parameters in the feed command Cause Incorrect number of parameters for a paging function Solution Correct command 6 20 000012 11 11 2009 jmu G3 Series Malfunctions 0x0001A703 0x0001A803 0x0001A903 0x0001AA03 0x0001AB03 0x0001AC03 0x0001AD03 0x0001AE02 0x0001AF01 0x0001B003 Error messages HAL Unknown Altera function HAL file line no 0s Contact service HAL Unknown Altera string HAL file row number 0s Contact service HAL It is not possible to configure a stop trigger at this Altera input HAL file row number 0s Contact service HAL Bit does not exist HAL file row number 0s Contact service HAL Insufficient bits available for the assigned function HAL file row number 0s Contact service An error occurred when parsing the HAL file Contact service Error in the status machine Contact service Deletion failed Tool is still assigned to a module Cause An attempt was made to delete a tool but the tool is still connected to a module and therefore cannot be deleted Solution The tool must first be removed from all modules A tool of this type and with this number already exists Cause An attempt was made to attach a tool but the attempted combination of tool type and too
147. service department if necessary Error Errors that can probably be remedied contact the service department if necessary Alarm Serious error contact the service department 000012 11 11 2009 jmu Malfunctions G3 Series Error messages 6 3 0x00000603 0x00001303 0x00004F04 0x00005403 0x00005503 0x00005803 0x00005A03 0x00005B02 0x00007702 Error messages Int err No msg could be sent Cmd 0s Index 1s Contact service An unknown parameter ID 0x 0s was requested from the internal database The parameter is not currently loaded or does not exist Contact service Software exception 1s 2s Contact service Unknown command Cmd ID 0s Contact service Err during msg release Sys Cmd ID 0s MQX error ID 1s Contact service Internal error An error occurred while waiting for a synchronous message Contact Service Internal error The pool for messages is full No message could be saved in the pool Contact Service Internal error A message queue is full The message has been deleted Contact Service Value outside of the validity range Min 0s Max 1s Cause Parameter outside of the defined limits HPGL 000012 11 11 2009 jmu G3 Series Malfunctions 0x00007B04 0x00007C04 0x00007D02 0x00008003 0x00008602 0x00008702 0x00008802 0x00008902 0x00008A02 0x00008B02 Error messages Solution Adjust parameter
148. ses only and is subject to change without notice at any time This does not constitute an obligation on the part of Z nd Systemtechnik AG No part of this document may be copied distributed used or disclosed to third parties without express permission Offenders will be liable for damages Troubleshooting hints and tips Important You can find information about troubleshooting and useful hints and tips on the Z nd homepage www zund com Documented cutter models This documentation applies for the following types of G3 series cutters G3 Series M line L line XL line 2XL line 3XL line M 1600 L 3200 XL 3200 2XL 3200 3XL 3200 M 2500 L 2500 XL 2500 XL 1600 2XL 1600 3XL 1600 Publishing details Name Operating manual for G3 series cutters side support version Composition illustration and publication Z nd Systemtechnik AG Technical Editorial Department Copyright Z nd Systemtechnik AG 000009 06 11 2009 jmu 1 7 Introduction G3 Series Publishing details 1 8 000009 06 11 2009 jmu G3 Series Product description 2 1 General Product description General This chapter contains information on the following Representational conventions in the operating manual Possible uses of the machine Structure of the main components Important technical data General technical description of the device Directional infor
149. setting is only valid for the automatic initialisation Pos Pressure mode Menu for modules which can be used in both the position mode and the pressure mode e g universal module Position mode In the position mode the cutting depth is defined using the zero point of the Z axis The module moves to the set zero point irrespective of the pressure the cutting depth Pressure mode The cutting depth is the result of a set pressure which is exerted on the tool by the module The module moves into the material until the preset pressure is reached Initialisation generally takes place on the material surface Then set the cutting depth with the Down Z pos function 1 1 1 3 4 2 Pos Pressure mode Display of the current mode Use the gt key to change to the selection menu and select the required mode X amp Y pressure Setting of the pressure in the X and Y direction Setting range 2 20 kg X pressure Setting of the pressure for the X axis Setting range 2 20 kg Y pressure Setting of the pressure for the Y axis Setting range 2 20 kg 5 8 000015 040 11 2009 jmu G3 Series Description of menu Description of menu 1 1 1 3 4 8 Auto init options Menu for the determination of the zero point with the automatic knife initialisation For further information see chapter Controls and operation in the operating manual Fig 5 5 Init tool settings 1 2 3 b 1 1 1 3 4 8 1 Init tool offset Zero poin
150. settings factory setting Limit values are available for many functions values Select function Use Min Max to set the value to the upper lower limit value 4 12 000010 09 11 2009 jmu G3 Series Controls and operation 4 4 2 4 4 3 4 4 4 Menu navigation Help Help texts are available for important menu entries In order to display a help text mark the required menu and press the x key Info menu Within the menu the Info menu can be activated with the key Use the lt gt keys to switch between tabs Use the A y keys to scroll up down within the tab Tabs Tab Information Head Information on the module carriage Module Information on the module Position Specification of the current position of the current tool Buffer Information on the memory system Job Information on the print job Status Display of the user level the operating status etc Function keys Allocation of the function keys Communication Communication settings such as interface port IP address mask MAC address etc Popups dialogues Popup menus dialogues are displayed for the following actions e Error messages dialogue e Cutter status display dialogue e Menus that are called up using function keys popup The system changes back to the previously active menu when a popup or a dialogue is closed 000010 09 11 2009 jmu Controls and operation G3 Series
151. suitable containers and dispo se of them in an environment friendly manner and only at official sites Observe the regulations applicable in your country 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Operating resources 7 3 2 7 3 3 7 3 4 Cleaning fluids Attention The use of incorrect cleaning fluids not approved by Z nd will damage the machine Only use cleaning fluids recommended by Z nd Systemtechnik Do not use abrasive cleaning fluids Caustic substances and scouring agents can damage surfaces of the cutter e g operating unit Cleaning fluids Place of use Plastic cleaning fluid Covers metal parts Lubricants X Y axis guide rails bearings This machine uses a specially adapted synthetic lubricant which is also used in the food and pharmaceutical industry This is characterised by good water resistance and corrosion protection and can be used at a temperature range from 25 C to 120 C Description Specification Kliiberoil 4UH1 Gears To lubricate the gears a Teflon special grease is used for precision gears in order to reduce friction Description Specification Fin Grease MP 2 3 Adhesives Conveyor belt Description Specification Korapur 784 5 Screw locking Only use adhesives for screw locking if this is specifically stipulated in the service manual
152. t light barrier height 4 AKI2 Knife in operating position 5 Cutting base Light barrier Init tool offset Correction factor for setting the processing depth This value can be used to adjust the cutting depth by 1 5 mm 1 1 1 3 4 9 Init Z pos Z position after initialisation This value is determined via the functions Define Z init pos 1 1 1 2 1 or Auto init 1 1 1 2 2 1 1 1 3 5 T axis settings Settings of the T axis E g universal module 1 1 1 3 5 1 Auto lift up angle If a direction change of more than the set value is detected during processing the tool remains in position is raised turns into the new processing direction is lowered again and accelerates 000015 040 11 2009 jmu Description of menu G3 Series Description of menu 1 1 1 3 5 2 1 1 1 3 5 1 1 1 3 5 2 1 1 1 3 5 3 1 1 1 3 5 4 1 1 1 3 6 1 1 1 3 6 1 1 1 1 3 6 2 1 1 1 3 6 3 Fig 5 6 Auto lift up angle A Processing direction W Movement angle Auto lift up angle A Example Movement angle following change in direction T axis rotation Switching the tangential rotation on and off Switch the function for the rotation of the T axis off if it is not required for the application e g use of marking tools Dust collector settings Setting of the parameters for modules with automatic dust collection position Display of the current height of the suction unit Offset Correction value for the adjustment of the positi
153. t user 4 14 000010 09 11 2009 jmu G3 Series Controls and operation 4 4 6 Menu navigation Function keys The cutter has function keys F1 F8 which can be allocated menu functions These keys can be selected via the menu or directly Allocate function keys directly gt Press the SHIFT key and the function key F1 F8 which you wish to change at the same time Function Key Editor for F 1 211 Ref point 4 options DO et A gt The window for function key selection opens gt Use the number field to enter the menu number of the required menu entry gt Confirm using OK or cancel using ESC Allocating the function key via the menu gt Select the menu Function keys 6 5 Enter the numbers 1 8 for the respective function key F1 F8 The window for function key selection opens Use the number field to enter the menu number of the required menu entry 1 g 2 28 Confirm using OK or cancel using ESC Resetting a function key to the factory setting gt Change to the menu Function keys6 5 gt The window for function key selection opens gt Press the DEF key in order to activate factory settings gt Confirm using OK or cancel using ESC 000010 09 11 2009 jmu Controls and operation G3 Series Functions 4 5 4 5 1 4 5 2 4 5 3 4 5 4 Functions Set language It is possible to select the display language of the cutter gt Select the Language 6 1 function from the m
154. tance between the measuring points Functions Functions for setting material hold down router dust extractor compressor 000015 040 11 2009 jmu 5 33 Description of menu G3 Series Description of menu 3 1 1 3 1 1 1 3 1 1 5 3 2 1 1 3 2 1 2 3 2 1 3 3 2 1 6 3 2 1 6 3 2 3 3 2 3 1 3 2 3 1 3 2 3 2 3 3 3 3 1 Vacuum Setting the material hold down by vacuum Vacuum status Vacuum status On Off Power level Select power level between 1 and 10 The power level is monitored by a vacuum sen sor and adapted to the requirements Rpm Display of RPM Increase RPM Use the gt key to increase the RPM Keep this key held down to increase the RPM more quickly Decrease RPM Use the gt key to decrease the RPM Keep this key held down to reduce the RPM more quickly Converter on The router converter is in standby mode gt must be pressed to switch the router converter on Converter standby The router converter is switched on gt must be pressed in order to activate standby mode Vacuum cleaner For turning the dust extractor on off Switch off Extractor is switched on gt must be pressed to switch the extractor off Switch on Extractor is switched off gt must be pressed to switch the extractor on Dust extraction Status display dust extraction on off Test functions Tests to verify the functionality and quality of the cutter Polygon test cut For
155. testing modules 5 34 000015 040 11 2009 jmu G3 Series Description of menu 3 3 2 3 3 3 O O gb252 O O O O O O O O O Description of menu Fig 5 18 Polygons approx 10 x 10 mm distributed over the entire work surface Square test cut For testing modules gb250 Fig 5 19 Squares approx 10 x 10 mm distributed over the entire work surface Circle test cut For testing modules 000015 040 11 2009 jmu 5 35 Description of menu G3 Series Description of menu 3 3 4 3 3 5 3 3 6 3 3 7 o O O O o o O O Q O O O O O Q O O O O O O o o o O O O O O o O O O O O O O O O O O O Ows O O O O O Fig 5 20 Circles diameter approx 10 mm distributed over the entire work surface Diagonal test cut For testing the drive elements belts bearings motors of the X and Y axis 9b253 Fig 5 21 Diagonal over the entire work surface Random line Continuous load test Random lines distributed over the entire work surface Random curve Continuous load test Random curves distributed over the entire work surface DIN Test 5 36 000015 040 11 2009 jmu G3 Series Description of menu Description of menu Quality test xxx XXX x x
156. the container and shut the drain screw 7 24 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs 7 7 12 Automatic circuit breakers Attention Danger of injury by electric shock Hazardous voltage in the power unit Do not remove the power box cover under any circumstances Contact your service partner if you have any problems with the energy supply Attention Danger of machine damage If an automatic circuit breaker has been triggered then there is an electrical defect in a consumer Remove the consumers which are secured by the circuit breaker that triggered from the stated list and allow them to be checked by authorised specialist per sonnel Never start up damaged machines Remove the cover Fig 7 15 Remove the cover gt Lift the cover and remove from the guide 000001 10 11 2009 jmu 7 25 Cleaning and maintenance G3 Series Maintenance jobs Automatic circuit breakers Li L2 L3 PBox Fig 7 16 Automatic circuit breakers Fuse Consumer L1 Cutter control compressor PC L2 Vacuum cleaner various options L3 Auxiliary drive router converter Important Maximum current 16 A phase 7 26 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs 7 7 13 Conveyor belt Tools and materials Conveyo
157. the vacuum generator Vacuum generator For additional data see rating plate original operating manual in chapter Additional specifications The vacuum generator is selected according to the following criteria Cutter model Desired application Local mains voltage and frequency Vacuum generator 1 9 KW Value Units Voltage 3 phase 400 V Mains frequency 50 60 Hz Power consumption 3 phases 1 9 KW Mains fuse min 32 A Vacuum generator 1 15 KW Value Units Voltage 3 phase 400 V Mains frequency 50 60 Hz Power consumption 3 phases 1 15 KW Mains fuse min 32 A Vacuum generator 1 9 KW Value Units Voltage 3 phase 208 V Mains frequency 50 60 Hz 2 18 000003 06 11 2009 jmu G3 Series Product description 2 8 3 2 8 4 2 8 5 Technical information Vacuum generator 1 9 KW Value Units Power consumption 3 phases 1 9 KW Mains fuse min 50 A Environmental conditions Value Unit Operating temperature 10 to 35 C Storage temperature 20 to 55 C Relative humidity 10 80 non condensing Basic device compressed air Conveyor feeding clamps Value Units Operating pressure 0 6 0 8 MPa Min air flow 5 3 gal min Setting pressure regulator maintenance unit 0 6 MPa P3 Control of vacuum zones supply of various Value Units modules tool
158. tion approx 30 min Camera Setting of the camera lighting The lighting is used to optimise the lighting conditions User settings Access to menus and functions is blocked according to the user level The user levels have a hierarchical structure This means that the next highest user also has the access rights to the menu functions that the subordinate user has 5 38 000015 040 11 2009 jmu G3 Series Description of menu Description of menu User Description Users 1 3 All menus and functions that are needed for the operation of the machine are accessible Operator Certain settings work is permitted Service Cutter settings that can only be carried out by authorised service personnel Factory setup Basic settings already implemented at Z nd 4 1 User gt Select user level and confirm with OK Press R gt Enter user code and confirm with OK 4 2 Password gt Enter your user code Y The user level is approved and is displayed under User4 1 4 3 Start user Setting of which user level is automatically active once the cutter has been started up 4 4 Change password 4 4 1 4 4 2 Change and save password for user 2 3 At least the operator user level must be active in order to change a password for these users User 2 Entry of a password for user 2 User 3 Entry of a password for user 3 000015 040 11 2009 jmu 5 39 Description of menu G3 Series Description of menu 5 Communic
159. to user tips and useful information which enhance the usability and prolong the service life of the machine and make the work significantly easier 000011 08 11 2009 jmu Safety G3 Series Hazard warnings important instructions 3 4 2 Structure of the hazard warnings Example Warning Risk of poisoning from the emission of toxic dust Processing certain materials can lead to the creation of toxic dust with significant risk to health e Obtain information about the toxicity of the material to be processed from the ma nufacturer e Use a suitable extraction unit or take other appropriate action accordingly Hazard warnings consist of the following units 1 The hazard symbol of the appropriate signal colour 2 The signal word corresponding to the danger resulting from the situation 3 The description of the danger 4 The description of the consequences which could result from this hazardous si tuation 5 Possible actions and codes of conduct to prevent the hazard occurring or to avert possible hazardous situations 000011 08 11 2009 jmu G3 Series Safety Areas of responsibility 3 5 Areas of responsibility The manufacturer Is responsible for the safe condition of the machine on delivery including instruc tion handbook and accessories according to the sales documentation The owner or person authorised by him Ensures that only adequately trained personnel who have been properly ins tru
160. utter must be switched off and the problem in the power unit must be remedied Solution It may be the case that the ventilation in the power unit is not correct Check for dirt and clean if necessary Unauth mod change This can lead to hazardous situations Always use Start module change to assemble or dismantle modules Cause A module was assembled or dismantled without the system being notified This can lead to a hazardous situation ACBug Controller data lost Contact service 000012 11 11 2009 jmu 6 25 Malfunctions G3 Series Error messages 0x0001D503 0x0001D604 0x0001D701 0x0001D803 0x0001D903 0x0001DA03 0x0001DB03 0x0001DC01 0x0001DE03 0x0001DF04 0x0001E002 Too many parameters selected for the ACBug output Contact service Flash access error Error number 0s Contact service Change to module 0s Module carriage moves Cause Information for the users that there is an automatic change to another module and that the module carriage is moving Mod supply VMOT could not be switched on The time was exceeded Contact service Mod amplification AMP could not be switched on Timeout Contact service The module backup could not be opened Contact service Option board not found Contact service This slot cannot be used Already occupied or not available Contact service The Z link synchronisation has not come about Contact serv
161. vers Fig 7 9 Remove the covers Push the bar forwards Remove the safety screws from the ends Important gt The covers are fastened onto the bar with Velcro gt Push the module carriage away from the cover Remove the cover 7 19 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs Cleaning the guide rails Fig 7 10 Cleaning the guide rails gt Clean the entire length of the guide rails using a lint free rag gt Soak a lint free rag with lubricant for guide rails bearings and oil the guide rails gt Fit all the covers 7 20 000001 10 11 2009 jmu G3 Series Cleaning and maintenance Maintenance jobs 7 7 8 Lubricating the Y axis bearing Tools and materials Lubricant for guideways X 4mm Allen key Clean lint free rags Cardboard base or drip tray Ensure that following preconditions are fulfilled 1 The machine is in the maintenance position L All modules have been dismantled from the module carriage Lubricate bearing Fig 7 11 Lubricate bearing Push the module carriage to the right until it stops Place a cardboard base or drip tray under the module Use the oiler to apply a drop of oil to the lubrication points Use a lint free cloth to remove excess oil from the module carriage L uu 2 1 7 21 000001 10 11 2009 jmu Cleaning and maintenance G3 Series Maintenance jobs 7 7 9 C
162. y be damaged Temperature 0s C Cause The temperature in the BF board exceeded a critical threshold This may cause damage to the hardware Solution Switch machine off and leave to cool down Contact service if this error occurs again Command currently not possible Cause An instruction waits for commands but is not able to process a prematurely received command Solution Try another time Contact the service department Undefined status of an instruction Contact service Error in the slide vacuum Communication error on an internal bus CAN 6 16 000012 11 11 2009 jmu G3 Series Malfunctions 0x00017803 0x00017A03 0x00017B02 0x00017C03 0x00017D04 0x00017E04 0x00017F03 0x00018003 0x00018202 0x00018302 Error messages Contact service Incorrect slide vacuum parameter Error index 0s Vacuum slider current limitation CAN message has been lost Contact service Incorrect module initialisation Status Contact service Operating unit has lost the communication to the MC CAN Tx error Contact service Operating unit has lost the communication to the MC CAN Rx error Contact service Error when looking for the zero mark of the T axis Contact service Distance outside of range Contact service Initialisation module stopped Cause The initialisation of a module was interrupted The head modules are set to an uninitialised status and can no

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