s91 Operator Manual

S-91 GERBERcutterOPERATOR AND MAINTENANCE MANUAL

i

Copyright 1998 by Gerber Garment Technology, Inc. All rights reserved.

This document may not be reproduced by any means, in whole or in part, without thewritten permission of the copyright owner.

This document is part of the proprietary articles furnished to document Gerber GarmentTechnology’s S91 GERBERcutter®.

In consideration of the furnishing of the information contained in this document, the party towhom it is given assumes its control and custody and agrees to the following:

1. The information contained herein is given in confidence and any part thereof shall notbe copied or reproduced without the written consent of Gerber Garment Technology,Inc.

2. This document or the contents herein under no circumstances shall be used in themanufacture or reproduction of the article shown and the delivery shall not constituteany right or license to do so.

The information contained in this document is subject to change without notice.

Gerber Garment Technology, Inc., its subsidiaries and affiliates shall not be liable for errorsin this documentation or for incidental or consequential damages in connection withfurnishing, or use of this material.

COMMAND, G (stylized logo), GGT, GERBER BRISTLE SQUARE, GERBERcutter,GERBERmover, Knife Intelligence, and MARKAMATIC are registered trademarks ofGerber Garment Technology, Inc.

AccuMark, AccuPlot, Booster PAK, GERBERmarker, GERBERplanner, GERBERsaver,GERBERspreader, IMPACT, MicroMark, and POWER Processor are trademarks of GerberGarment Technology, Inc.

Windows NT is a registered trademark of Microsoft Corporation.Baldor is a registered trademark of Baldor Electric CompanySpencer is a registered trademark of Spencer Turbine Company

Other company names, brand names, and product names mentioned in this book arerecognized as trademarks or registered trademarks of their respective companies.

Gerber Garment Technology, Inc.24 Industrial Park Road WestTolland, CT 06084 USA

Printed in USA 2/98Document Number 083878000

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What’s Inside............................................................................................................................................. ixConventions.............................................................................................................................................xProduct Support ..................................................................................................................................... xi

Safety Precautions....................................................................................................................................xiii

1 S91 GERBERcuttersAvailable Models........................................................................................................................................ 1

Traveling Conveyorized (TCW) ............................................................................................................. 1Static ....................................................................................................................................................... 2Zoned Valve Conveyor (ZVC)................................................................................................................ 2

Major Subsystems....................................................................................................................................... 3C200 Controller ...................................................................................................................................... 3Cutting Table.......................................................................................................................................... 3

Cutter Head and Beam Assembly........................................................................................................ 4Work Surface...................................................................................................................................... 5Vacuum Assembly .............................................................................................................................. 6Limit Switches .................................................................................................................................... 7

Operator Controls ................................................................................................................................... 7Emergency Stop.................................................................................................................................. 8Circuit Breakers................................................................................................................................ 10Platform and Conveyor Controls....................................................................................................... 11Beam Control Panel .......................................................................................................................... 13

Operator Workstation............................................................................................................................ 15Options.................................................................................................................................................. 16

Spare Cutter Head (Without Covers) ................................................................................................ 16Spare Sharpener Assembly................................................................................................................ 16Right Side Option.............................................................................................................................. 17Electric Drills.................................................................................................................................... 17CTOT................................................................................................................................................ 17Cutter Info Database (CIDB) ............................................................................................................ 18POWER Processor............................................................................................................................ 18

2 Basic ConceptsDirection and Location.............................................................................................................................. 19

Ends and Sides...................................................................................................................................... 19X, Y, and C–Axes................................................................................................................................. 20

Origin........................................................................................................................................................ 21Bite Feeding.............................................................................................................................................. 23Software and Files..................................................................................................................................... 25

Software................................................................................................................................................ 25Cut File ................................................................................................................................................. 25Setup ..................................................................................................................................................... 25

3 Cutting MarkersSpreading Material .................................................................................................................................... 28Basic Cutting............................................................................................................................................. 29

Turning on the Cutter............................................................................................................................ 30Enabling Servo Power........................................................................................................................... 31Initializing the Cutter ............................................................................................................................ 32Positioning the First Bite....................................................................................................................... 33

On TCW and ZVC Systems.............................................................................................................. 33

iv

On Static Systems..............................................................................................................................33Selecting a Setup...................................................................................................................................35Opening a Marker..................................................................................................................................36Turning on the Vacuum.........................................................................................................................37Turning on the Laser Light....................................................................................................................37Setting the Marker Origin......................................................................................................................38Selecting Cutting Speed ........................................................................................................................39Turning on the Knife Motor ..................................................................................................................39Processing a Marker ..............................................................................................................................40Exiting the Program...............................................................................................................................41

Beyond the Basics.....................................................................................................................................42Using Fabric Alignment ........................................................................................................................42Using Pause Between Bites...................................................................................................................43Using Check Origin...............................................................................................................................43Using X Data Scale Factor, Y Data Scale Factor ..................................................................................44Using Move To Origin..........................................................................................................................44Using Trim Cut......................................................................................................................................45

Recovery from Interrupted Cutting ...........................................................................................................46Before Using Recovery Commands..................................................................................................46

Using Restore State...............................................................................................................................47Restoring State Manually ..................................................................................................................48

Using Piece Search................................................................................................................................49Using Piece Recut .................................................................................................................................49Using Restore Origin.............................................................................................................................50Using Bite Search..................................................................................................................................50

4 UtilitiesParameter Manager ...................................................................................................................................52

Access Levels by Password...................................................................................................................52Parameters and Categories....................................................................................................................52

Run Time Biting........................................................................................................................................54Static Length Biting...............................................................................................................................54Variable Length Biting..........................................................................................................................54

PreProcessor..............................................................................................................................................55Reorder..................................................................................................................................................55Common Line........................................................................................................................................55Path Optimization..................................................................................................................................55

View Marker .............................................................................................................................................56Selecting Pieces.....................................................................................................................................56

Tool Code Reference.........................................................................................................................56Playing Back a Marker ..........................................................................................................................56

Animate.............................................................................................................................................56Piece by Piece...................................................................................................................................56Segment by Segment .........................................................................................................................56

Queue Manager .........................................................................................................................................57Job Queues............................................................................................................................................57Defaults for Queue Manager .................................................................................................................57

File Manager .............................................................................................................................................58Directories and Files..............................................................................................................................58

Using Paths to Locate Files...............................................................................................................58Using Wild Cards to Locate Files .....................................................................................................59

Locking File Manager ...........................................................................................................................59Cutter Information Database (CIDB) ........................................................................................................60

v

Marker Report Types............................................................................................................................ 60Partial Marker Report ....................................................................................................................... 60Marker Reports................................................................................................................................. 61Shift Reports..................................................................................................................................... 61

5 Optimizing Cutter PerformanceSharpening and Replacing the Knife......................................................................................................... 63

Automatic Sharpening........................................................................................................................... 64Sharpening When the Cutter is Idle...................................................................................................... 64Resetting for New Knife ....................................................................................................................... 65Setting Knife Speeds............................................................................................................................. 66

Using Knife Intelligence........................................................................................................................... 67KI Settings............................................................................................................................................ 67Nulling Knife Intelligence Sensor......................................................................................................... 67

Using Path Intelligence............................................................................................................................. 69Path Intelligence Diagnostics................................................................................................................ 69

Controlling Vacuum Levels...................................................................................................................... 70Energy Savings Mode........................................................................................................................... 70

6 MaintenanceSafety Precautions............................................................................................................................. 72

Maintenance Procedures........................................................................................................................... 73Basics................................................................................................................................................ 73Advanced .......................................................................................................................................... 73Electrical ........................................................................................................................................... 73

General Maintenance............................................................................................................................ 74Cleaning............................................................................................................................................ 74Lubrication........................................................................................................................................ 74

Ordering Spare Parts............................................................................................................................. 74Tools Available from GGT................................................................................................................... 75

Additional Tools............................................................................................................................... 75S91 TCW Illustrations.......................................................................................................................... 76S91 Static Illustrations.......................................................................................................................... 77S91 ZVC Illustrations........................................................................................................................... 77

Maintenance Summary and Schedule........................................................................................................ 798 Hour Maintenance Schedule.............................................................................................................. 7940 Hour Maintenance Schedule............................................................................................................ 85160 Hour Maintenance Schedule.......................................................................................................... 91960 Hour Maintenance Schedule.......................................................................................................... 97

Cutter Head............................................................................................................................................. 103Cover................................................................................................................................................... 103Knife Drive Train................................................................................................................................ 104Knife................................................................................................................................................... 106Sharpener Assembly............................................................................................................................ 107Knife Guides and Offset...................................................................................................................... 109

Knife Guides................................................................................................................................... 109Knife Offset..................................................................................................................................... 110

Elevator............................................................................................................................................... 112Elevator Guide Rods....................................................................................................................... 112Air Cylinder Rod............................................................................................................................. 112Head Stops...................................................................................................................................... 112

C–axis Drive....................................................................................................................................... 113Servo Gear ...................................................................................................................................... 113Drive Belt........................................................................................................................................ 113

vi

Knife Drive..........................................................................................................................................113Tension and Pivot Arm Oil Cups....................................................................................................113Knife Drive Gearing and Belts........................................................................................................114Knife Drive Motor...........................................................................................................................115Knife Speed.....................................................................................................................................115

Electric Drill ............................................................................................................................................116Drill Bi t ...............................................................................................................................................116Drill Assembly ....................................................................................................................................118

Air Cylinder.....................................................................................................................................118Drive Belt ........................................................................................................................................118Drive Motor.....................................................................................................................................119Drill Speed ......................................................................................................................................119

Beam .......................................................................................................................................................121Roundway and Squareway ..................................................................................................................121Covers.................................................................................................................................................122Basic X–axis and Y–axis.....................................................................................................................122

Servo Motor Gearing.......................................................................................................................123Servo Pinion Gearing and Torque Tube Belts.................................................................................123Y–axis Countershaft Gear ...............................................................................................................124Wheel Housing Cam Rollers...........................................................................................................125Wheel Assemblies...........................................................................................................................125Bite Encoder....................................................................................................................................125

Advanced X–axis and Y–axis .............................................................................................................126Roundway Bearings.........................................................................................................................126Squareway Bearings........................................................................................................................126Spring Scale Tests...........................................................................................................................127Y–axis Drive Belt Tension..............................................................................................................128Squaring the Beam ..........................................................................................................................129

Table .......................................................................................................................................................130Work Surface......................................................................................................................................130Work Surface Cleaner .........................................................................................................................132

Gear Box .........................................................................................................................................132Pillow Block Bearings.....................................................................................................................132

Roundways and Racks.........................................................................................................................133Roundways......................................................................................................................................133Racks...............................................................................................................................................133

Filters ..................................................................................................................................................134Vacuum Filter..................................................................................................................................134Stack Filter ......................................................................................................................................134Air/Reducer Filter ...........................................................................................................................135

Vacuum Assembly...............................................................................................................................135Cover...............................................................................................................................................135Motor and Generator .......................................................................................................................136Drive Belt Tensioning.....................................................................................................................136Coupling Alignment ........................................................................................................................137

Material Handling Systems.................................................................................................................138Clamp Bar .......................................................................................................................................138Resealer ...........................................................................................................................................138Conveyor Drive Gear Box...............................................................................................................139Conveyor Drive...............................................................................................................................139Lay Puller Gear Box........................................................................................................................139Lay Puller Drive..............................................................................................................................140

Platform...............................................................................................................................................141

vii

7 TroubleshootingProduct Support .............................................................................................................................. 143

Error Messages ....................................................................................................................................... 144Class 1 FEP Errors.............................................................................................................................. 145Class 1 MCC Errors ............................................................................................................................ 146Class 2 Errors...................................................................................................................................... 147Class 3 Errors...................................................................................................................................... 148Class 4 Errors...................................................................................................................................... 148

Diagnostics.............................................................................................................................................. 149Selecting Diagnostics ...................................................................................................................... 151

Input Output Test (DG 23).................................................................................................................. 151KI Calibration (DG 20)....................................................................................................................... 152C Home to System Zero Diagnostic.................................................................................................... 154Cut Tests ............................................................................................................................................. 155Beam Square Test ............................................................................................................................... 156Heel to Heel Test ................................................................................................................................ 157Knife Offset Setup .............................................................................................................................. 158

Training (CBT) ....................................................................................................................................... 159Service Parts ........................................................................................................................................... 159CAM Applications .................................................................................................................................. 160

Automated Cutting Concepts .............................................................................................................. 160Data Preparation ............................................................................................................................. 161Vacuum Hold Down ....................................................................................................................... 162Knife Sharpening ............................................................................................................................ 162Motion Control................................................................................................................................ 162

Glossary ............................................................................................................163

Appendix ...........................................................................................................169

What’s Inside ix

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This manual contains information on using the S91 GERBERcutter. It includesthe following chapters:

Safety Precautions

This introductory chapter details safety precautions you must follow whenoperating the S91 GERBERcutter. Read this section before you start cutting.

Chapter 1 S91 GERBERcutters

This chapter provides an overview of the three models of S91 GERBERcutters,including major components and optional equipment.

Chapter 2 Basic Concepts

This chapter discusses basic ideas you need to understand in order to use thisautomated cutting system.

Chapter 3 Cutting Markers

This chapter describes the basic steps required to start up the system, cut a markeror cut file, and shut down the system. Recovery procedures are also covered.

Chapter 4 Utilities

This chapter introduces utilities in the C200MT program that help you manage cutfiles and utilize the multitasking capabilities of the program.

Chapter 5 Optimizing Cutter Performance

This chapter covers how to quickly access settings in the C200MT program thatoptimize GERBERcutter performance for the current cut file.

Chapter 6 Maintenance

This chapter covers preventative and corrective maintenance procedures for S91GERBERcutters. Included are maintenance schedules of procedures that GGT

recommends be performed regularly after 8, 40, 160, and 960 hours of operation.

x What’s Inside

Chapter 7 Troubleshooting

This chapter suggests several ways to obtain help if you ever experienceGERBERcutter performance that is less than expected. Error messages,diagnostics, and other support and application information are covered briefly.

Glossary

The Glossary lists terms you need to know.

Index

The Index provides an alphabetical listing of topics of interest in this manual.

Conventions

The following conventions are used throughout this manual:

Bold type highlights important information in the text.

Italic type highlights titles of other manuals.

Note: Notes contain important or helpful information.

CAUTION: Cautions appear before procedures that could cause damage toequipment or material if you do not do them correctly.

WARNING! Warnings tell you when you must follow a specificprocedure or practice to av oid p ersonal injury or death.

What’s Inside xi

Product Support

As a part of our commitment to excellence, GGT provides complete productsupport for GERBERcutters, worldwide.

Inside the United States and Canada

For product support within the United States or Canada, call:

1-800-999-1448

For information about training or other products, call the GGT Sales and ServiceOffice in your area.

Have the following information ready when you call:

• Identify what equipment you are using.

• Identify any special equipment or software you are using, such as the drilloption.

• Identify what software packages you are using. Include the softwareversion numbers.

Outside the United States and Canada

For software/hardware support, training, or information about products outside ofthe United States and Canada, call your local GGT Sales and Service office.

xii What’s Inside

Safety Precautions xiii

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About This Section

This section details safety precautions you must follow when operating theS91 GERBERcutter.

WARNING! Failure to follow these safety precautions could result ininjury or death.

Dangerous Procedure Warnings

Warnings precede potentially dangerous procedures throughout this manual.Instructions contained in warnings must be followed. You also should employall other safety precautions that you deem necessary for safe operation of theequipment in your operating environment.

Do Not Perform Maintenance Alone

Do not perform any maintenance on the equipment unless another person thatcan render first aid and resuscitation is present.

Live Circuits

High voltages exist inside the C200 controller/vacuum electronics enclosure.Never perform any work inside the vacuum electronics enclosure. There are nooperator–serviceable parts. Two power cables enter this enclosure: a three–phase cable for the vacuum generator system and a single–phase power cable forthe C200 controller. Both power cables must be disconnected before it is safe towork within the enclosure. There must be a main disconnect that meets localelectrical codes for each power supply.

xiv Safety Precautions

Turn Off Power Before Maintenance

To prevent accidental start–up, always turn off all power by shutting off circuitbreaker 1 before doing any maintenance.

Laser Origin Light

The origin light in the cutter head uses a laser light that points toward the cuttingsurface. When viewed as intended (by looking at the dot projected on thematerial to be cut), the laser should pose no hazard to operators. However, theorigin light is a Class IIIa laser product, with a peak power of 5 mW at awavelength of 670 nm. Never look straight into the light source of this laserbeam; doing so may cause temporary, or even permanent, damage to your eyes.Direct, bright reflections from the laser may also be harmful. Remove allhighly–reflective material (such as jewelry and mirrors) from the cutting surfacebefore turning on the origin light. Turn off the origin light before performing anymaintenance on the GERBERcutter.

WARNING! Use of controls or adjustments or performanceof procedures other than those specified herein mayresult in hazardous radiation exposure.

CircuitBreaker 1

Safety Precautions xv

Moving Machinery

Keep hands away from the Resealer and other moving machine parts to avoidpersonal injury. Make sure there is no one else near the table when you areoperating the GERBERcutter.

Replacing Parts

Report any broken or missing parts to your Field Service representative. Becauseof the danger of introducing additional hazards, do not install substitute parts orperform any unauthorized modification of the equipment.

Knife Blade

The knife blade is very sharp. Be extremely careful when working near the knifeblade.

Clothing

Loose–fitting clothing, dangling neck chains and ties, loose jewelry, and longhair can be a hazard when working around machinery.

Compressed Air

Always use caution when using compressed air. Never use compressed air toblow lint and dust off clothing or skin.

Lint

Avoid breathing in lint when changing the table and stack filters. Wear a masksuitable for this purpose.

xvi Safety Precautions

Equipment Training

Never attempt to operate this machinery unless you have received formaltraining to do so.

Do Not Operate in an Explosive Atmosphere

Use extreme caution when handling flammable liquids such as cleaningsolvents. Do not operate the equipment in the presence of flammable gases orfumes.

Use Caution When Handling the Monitor

The monitor on the operator workstation is a cathode–ray tube (CRT). Breakinga CRT could cause it to implode and scatter glass fragments at a high velocity.To prevent CRT implosion, avoid rough handling or jarring of the equipment.

Chapter 1 S91 GERBERcutters Page 1

1�6��*(5%(5FXWWHUVThe S91 GERBERcutter is a computer–controlled cutting system that cutsspreads with a compressed ply height up to 7.6 cm (3.0 in.). It automates theentire cutting process, replacing hand–held cutters, templates, and patterns.Instead of patterns, the GERBERcutter uses computer data files called cut filesto guide its knife. These cut files are made on Gerber marker making systemssuch as AccuMark or MicroMark. Computer–aided accuracy meansaccurate notches and pieces so sewing operators waste little time matching parts.

Available Models

The S91 is available in static, traveling conveyorized (TCW), and zoned valveconveyor (ZVC) models. Although these models share the same cutter controlsoftware, each is meant for specific applications, such as high ply, denim, orfoam. These models also have some mechanical differences.

Traveling Conveyorized (TCW)

TCW systems have a moveable work surface (conveyor) and the entire cuttermoves laterally across the factory floor on metal rails to service severalspreading tables. The conveyor lets this system cut spreads much longer than thecutting table. TCW systems have a material clamp and a built–in vacuumgenerator.

Conveyor

MaterialClamp

Platform andConveyorControls


Static

The Static system has a stationary work surface and is fixed in place on thefactory floor. The base system has a single cutting table with a motorized laypuller (not shown) and external vacuum generator (not shown). Mechanicallycontrolled vacuum zoning applies vacuum only to the area of the table surfacewhere the spread is being cut. This feature improves cut quality and lowerspower usage.

Zoned Valve Conveyor (ZVC)

The ZVC system has a moveable work surface (conveyor) which is fixed inplace on the factory floor. The conveyor lets this system cut spreads muchlonger than the cutting table itself. The ZVC has an external vacuum generator(not shown). Software controlled vacuum zoning applies vacuum only to thearea of the table surface where the spread is being cut. This feature improves cutquality and lowers power usage.

StationaryWork Surface

Conveyor


Note: Unless otherwise noted, information in this chapter applies to all S91models.

Major Subsystems

The S91 GERBERcutter has two major subsystems that work together to cutmaterial. These subsystems are the C200 controller and the cutting table.

C200 Controller

The C200 controller is the command center of the GERBERcutter. UsingC200MT software, the controller tells the cutting table how to cut material. TheC200 has two components that work together: the Front End Processor (FEP) orPC and the motion control computer (MCC). Located in the operatorworkstation, the PC lets you communicate with the GERBERcutter. It sendsyour instructions and cut file data to the MCC. The MCC then uses theseinstructions to run the cutting table.

Cutting Table

The cutting table cuts material according to instructions from the C200controller. All S91 models have these major parts:

• Cutter head and beam assembly.

• Beam control panel.

• Work surface.

• Vacuum generator.

• Mast (exhaust stack).

Other major parts depending on the model include:

• Conveyor.

• Lay puller.

• Limit switches.

• Platform controls.


Cutter Head and Beam Assembly

The cutter head and beam assembly cuts material by moving a reciprocatingknife across the work surface. The assembly moves in response to commandsfrom the C200 controller. The cutter head holds the knife which bothreciprocates and turns to cut corners, curves, and notches. The cutter headmoves across the width of the cutting table on a beam. The beam also travels thelength of the cutting table. By combining these movements, the GERBERcutteraccurately cuts complex patterns.

A laser origin light on the cutter head lets you position the knife to start cuttingat the right place. To do this, the origin light shines a point onto the material.

The beam control panel is a terminal that lets you control the GERBERcutterfrom the cutting table. For details on the types of beam control panels for S91cutters, see the Beam Control Panel section later in this chapter.

Cutter Head

Beam Assembly

Beam ControlPanel

OperatorWorkstation

WorkSurface

Laser Light


Work Surface

The work surface holds material for cutting. It is made of GERBER BRISTLESQUARES that fit into plastic grids on Static systems or into aluminum slatson conveyorized (TCW and ZVC) systems. BRISTLE SQUARES are squares ofmolded bristle that plug into the plastic grids or slats. Each bristle square hassmall holes in its base. When you apply vacuum to the cutting table, air passesthrough these holes to hold down the material.

BRISTLESQUARESwith Slats

BRISTLESQUARESwith Grids


Vacuum Assembly

To supply vacuum, the GERBERcutter uses either an external or built–invacuum generator. The vacuum generated is used to hold the material firmly onthe work surface during cutting. An external vacuum generator is connected tothe cutting table by a long duct; the built–in vacuum generator on a TCW islocated under the take–on end.

The figure above shows air flow in a static or ZVC with an external vacuumgenerator. The vacuum generator draws air through the BRISTLE SQUARES.From there, the air travels through vacuum vents into a plenum in the cuttingtable, and through a duct to the external air filter and vacuum generator. The airfinally exits through a remote exhaust stack, possibly located outside of thebuilding.

The figure above shows air flow in TCW systems with a built–in vacuumgenerator. In this case, air flows through the BRISTLE SQUARES and into theslats. From there it flows through the frame of the cutting table to the air filterand vacuum generator. The air finally exits through an exhaust stack (mast)located on the cutter.

StackBRISTLE SQUARES

and Slats

BRISTLE SQUARES

Air Filter VacuumGenerator

VacuumValve Duct


Limit Switches

Limit switches set limits for how far the cutter head and beam can move on thecutting table in the +X, -X, +Y, and -Y directions. The limit switches also tellthe C200 controller when the cutter head reaches the X0,Y0 coordinate whenyou initialize the system. Each limit switch is activated by a specifically placedmagnet or small metal plate.

Example: A limit switch located on the operator side of the work surface limitscutter head movement by sensing when it has reached the home position.Further cutter head movement in this direction would not be allowed by theC200 controller.

Operator Controls

Operator controls let you give commands to your GERBERcutter and respond tosystem messages. These controls are the:

• Emergency stop (EStops) switches and plungers.

• Circuit breakers.

• Table motion controls.

• Beam control panel.

• Operator workstation.


Emergency Stop

Emergency Stop (EStop) is a safety feature. You must know how to use EStopsbefore operating the GERBERcutter. An EStop halts all table motion in case ofdanger to people, the GERBERcutter, or the material being cut.

Pressing an EStop switch or plunger immediately shuts off all power to theconveyor, vacuum generator, cutter head, and beam. All motion stops. Only theoperator workstation stays on. You must perform a recovery procedure beforeyou can use the GERBERcutter again. The figure below shows typical EStoplocations.

EStop Switches — EStop switches are large red buttons. An EStop switch islocated on the operator workstation and the beam control panel. Additionalbutton locations depend on the model.

To stop the system:

1. Press one of the red EStop switches.

All table motion stops.

2. For error recovery procedures, see chapter 3 or refer to the C200MTSoftware User’s Guide.

CAUTION: Do not move the spread or jog the conveyor after anEStop. If you do, it will be very difficult for the cutter tostart cutting in the right place.

EStopSwitches

EStopSwitches

EStopPlungers


EStop Plungers — EStop plungers (sometimes called paddles) are large yellowbuttons strategically located on the beam. They depress automatically wheneverinterference is encountered, such as someone leaning against the table when thebeam is moving in that direction.

EStopPlungers


Circuit Breakers

The GERBERcutter has two main circuit breakers located on the electricalpanel. The electrical panel may be located on the side of the cutting table or on aseparate table along side the cutting table. Both circuit breakers must be turnedon for the system to run properly.

Circuit breaker 1 provides power to the C200 controller, servo motors, andconveyor. It is in the upper left corner. You use this circuit breaker to turn on theGERBERcutter.

Circuit breaker 2 provides power for the vacuum generator. It is located in thevacuum electrical enclosure. This circuit breaker is always left on.

WARNING! Do not turn circuit breaker 2 on or off. Highvoltages exist within the vacuum electrical enclosure andinside the C200 controller. Never perform any work inside thevacuum electrical enclosure. There are no operator–serviceableparts inside.

High VoltageSymbol

HazardSymbol

CircuitBreaker 1

Circuit Breaker 2(behind door)


Platform and Conveyor Controls

Depending on the model of your S91 cutter, platform controls (for TCW) andconveyor controls (for TCW and ZVC) are provided on the operator side of thecutter at the take–on end of the table.

TCW systems have table motion control switches similar to those shown aboveto move the conveyor and the cutter. Table motion controls on your cutter caninclude:

Vacuum Readout — Use to monitor vacuum pressure; your cutter may have adigital readout instead of the pneumatic readout (shown).

Platform Controls — Use to control movement of the cutter along railspositioned between two or more spreading tables.

• Forward — Moves the table forward laterally to align it with a spreadingtable or take–off table.

• Reverse — Reverses table movement laterally for alignment purposes.

• Brake — Locks the table in place after positioning; ON sets the brakesand OFF releases the brakes.

Power — Use to turn on power to the platform drive motors, as well as thevacuum generator and conveyor. On RSO TCW systems, this one control islocated as shown; however, platform and conveyor controls are located on apanel near the stack. See page 17.

Some units have power buttons (shown) while others have key switches. To turnpower on with a key switch, insert the key and turn it to the left; to turn offpower, turn the key to the right and remove it.

Vacuum Readout

EStopConveyor Controls

Platform Controls

Power Button


EStop — See earlier section in this chapter.

Conveyor Controls — Use to move spreads onto the conveyor and along thecutting table.

• Mode — Switches between Manual, Auto, and Reverse modes. InManual mode the conveyor moves forward toward the take–off endwhen you jog a spread. In Auto mode, the conveyor moves in responseto commands from the C200MT program. In Reverse mode, theconveyor moves backward toward the take–on end when you jog.

• Jog Control — Moves the conveyor backward or forward depending onhow the Mode switch is set. Do not use this switch while the cutter isprocessing a cut file.

• Blower — Controls whether or not air is blown up through theBRISTLE SQUARES to assist in moving a spread. If Manual isselected, the vacuum generator must be turned ON and OFF manually toblow air when you jog. If Auto is selected, the vacuum generator blowsair automatically when you jog.

• Vacuum — Controls the level of table vacuum by opening and closingthe dump valve on the table. Select Dump to open the dump valve,dropping table vacuum immediately. Select Auto to allow the C200MTprogram to control vacuum level by automatically opening and closingthe dump valve.


Beam Control Panel

The beam control panel (BCP) lets you control the cutter head, beam, andcertain table functions from the cutting table. Two examples of beam controlpanels are shown below.

Note: Certain controls on the beam control panel correspond to certain iconkeys on the operator workstation. Refer to the C200MT SoftwareUser's Guide for further details.

The table on the following page explains how to use the switches and othercomponents on the beam control panel.

Flat Panelon Static Cutter

Typical Panel


Component Description

EStop — Immediately stops all table motion.

Knife — Turns the knife motor on or off.

Manual Mode Light — Checks for head and beam movement; lights upwhen the head and beam are both stopped.

Feedrate Dial —Sets the feed rate at which the cutter head and beammove across the table. The range is from 1 (minimum) to 15(maximum); 0 is no movement. Cutting speed is the same as feed rate.

Joystick — Moves (slews) the cutter head and beam in the direction ofthe arrows. (-X, +X, -Y, or +Y); the Slew Enable switch must first bedepressed.

Slew Enable — Allows movement of the cutter head and beam; depressand hold before using joystick.

Error Warning Light — Checks joystick functions; lights up when thecutter is in Manual Bite or Trim Cut mode or when a controller erroroccurs.

Stop — Stops the current operation of the cutter.

Vacuum — Turns cutting table vacuum ON or OFF.

KI Null — Resets Knife Intelligence.

Fabric Alignment — Sets fabric alignment when pressed twice.

Manual Bite — Switches between Manual Bite mode and Auto mode.

Initialize — Moves the cutter head to the home X0,Y0 position on thetable.

Trim Cut — Manually trims the edges of a spread.

Origin — Sets the current position of the origin light as the origin ofyour marker. Marker origin is the X,Y coordinate where the markerstarts.

Note: The C200MT program takes into consideration the mechanicaloffset between the knife and the origin light.

Start — Starts the GERBERcutter.

Sharpen Knife — Manually sharpens the knife blade one cycle.


Operator Workstation

You use the operator workstation and the beam control panel to run theGERBERcutter. The operator workstation on your cutter looks similar to thefigure shown below. The operator workstation may also be called front endprocessor (FEP) or PC.

Monitor — Receives computer video signals from the PC and displaysinformation on the screen.

Speakers — For use with Computer Based Training.

Keyboard — Device with keys, like those on a typewriter, that lets you enterdata and communicate with the C200MT program.

Icon (function) keys — Each key performs a C200MT command to operate thecutter. The icon (picture) and color of the key tells you which key performs eachfunction. Refer to the C200MT Software User's Guide.

Pointing device — Moves the cursor around the screen to select cut files,setups, or pieces and enter menu commands and information in dialog boxes.Your pointing device may differ from the one shown above; refer to theC200MT Software User’s Guide.

Monitor

Speakers

Keyboard

Icon KeysServo PowerEnable

CD–ROM Drive3.5 in. Disk Drive

Pointing Device

EStop

Hard Drive

Speakers


Servo power enable — Pushing this button turns on power to the servo motors.These are motors that move the cutter head and beam as the GERBERcutter cutsmaterial.

Emergency stop — See section earlier in this chapter.

3.5 inch disk drive — C200MT software and cut files are stored on disksbefore being copied into the hard drive of the operator workstation PC. Diskscome in two sizes: 3.5 and 5.25 inches.

CD–ROM drive — Use for accessing Computer Based Training and ServiceParts; see chapter 7 and check availability with your local GGT Sales andService office.

Hard disk drive — The hard disk drive holds the C200MT software that runsthe GERBERcutter. A hard disk drive uses rigid metal disks so it can store muchmore data than a 3.5 inch disk.

You need to manage your hard disk so it does not become too full anddisorganized. Refer to Windows NT documentation and the C200MT SoftwareUser’s Guide for information on managing files on the hard disk.

Options

There are many options for tailoring the S91 to the material you cut and yourway of doing business. Here is a partial list of hardware and software that maybe useful as you become more familiar with your system. For more information,call your local GGT Sales and Service office.

Spare Cutter Head (Without Covers)

This cutter head replaces the cutter head running on the system to ensureminimum downtime during maintenance and repairs.

Spare Sharpener Assembly

This sharpener assembly replaces the sharpener assembly running on the systemto ensure minimum downtime during maintenance.


Right Side Option

The right side option lets you run the GERBERcutter from the right side of thecutting table. This lets you spread material with its straight edge on the rightside, which is more practical for some applications. Operator controls are movedto the right side where appropriate. Shown below is a TCW system with theRSO option.

Electric Drills

Electric drills are available as single, dual, and heavy duty units. GGT alsoprovides drill bits in a wide variety of sizes and types.

CTOT

A Conveyorized Take Off Table is available for use with the TCW and ZVCmodels. The CTOT AUTO Enable control is located on the operator’s side ofthe CTOT.

Conveyor andPlatform Controls

Beam ControlPanel


Cutter Info Database (CIDB)

CIDB is an optional time reporting software that helps you judge how well youare using your GERBERcutter. CIDB records how long various cutting activitiestake and provides reports that can help you decide how you can do things better.For example, CIDB may show that a certain cut file keeps the knife out of thematerial too long, increasing cutting time. These are some of the data CIDBrecords:

• Marker being cut.

• Cutting speed.

• Cutting time (blade in the material).

• Dry haul time (blade out of the material).

• Cutter stop time while cutting a cut file.

• Time used to prepare and align next spread.

POWER Processor

The POWER Processor lets you change cut files so that the GERBERcutterworks more efficiently. Input to the POWER Processor is a cut file produced ona marking and grading system such as GGT’s AccuMark or MicroMark. Outputis a modified cut file. Altering a cut file can improve cut quality, cut speed,material use, and cut file efficiency. The POWER Processor lets you:

• Change piece cutting sequence.

• Change the start point of a piece.

• Add or remove knife lift and plunge points.

• Add or remove Optional Stop points for plaid/stripe matching.

Note: Some features of the POWER Processor are now included in thePreProcessor utility of the C200MT program. See chapter 4.

Chapter 2 Basic Concepts Page 19

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Note: Information in this chapter applies to all S91 models unless otherwise noted.

Direction and Location

GGT uses specific terms to describe direction and location on the cutting table.Learning these words will make it easier for you to find your way aroundthe GERBERcutter.

Ends and Sides

Each side of the cutting table is named so you can identify it easily. The take–onend is where material comes onto the work surface for cutting. The take–off endis where material leaves the work surface after cutting. The right and left sidesare as they would appear to someone standing at the take–on end.

Take–on End(Right End on Static)Take–off End (ZVC / TCW)

Left End (Static)

Beam ControlPanel

Left Side

Right Side(Far Side)


X, Y, and C–axes

The GERBERcutter uses three imaginary lines or axes to tell direction andlocation on the cutting table. They are the X, Y, and C–axes, as shown below.

If you stand at the operator workstation, the Y–axis runs across the table, theX–axis goes from left to right, and the C–axis is in the cutter head. The beammoves along the X–axis, the cutter head travels the Y–axis, and the knife turnsaround the C–axis in the cutter head.

Movement is always in a plus (+) or minus (-) direction on the X and Y–axes.If you stand at the operator workstation:

• +X is to your right.

• +Y is away from you.

• -X is to your left.

• -Y is toward you.

Location is also given in terms of the X and Y–axes, as shown below.


If you stand at the operator workstation, the point X0, Y0 is at the lower leftcorner of the work surface, as shown below.

All locations on the work surface are relative to this position. Unlike direction,location is always stated in positive numbers. To find the point (X=24 in., Y=36in.), start at X0, Y0. Measure 24 in. to the right along the X–axis. From there,measure 36 in. away from you on the Y–axis . You are now at the pointX24, Y36.

Origin

Just as the table has a X0, Y0 position marking its lower left corner, so doeseach marker. The X0, Y0 position of the marker is called the origin. All datapoints (locations) of the marker are relative to the origin.

Before the GERBERcutter can cut a marker, you must set the location of theorigin. The cutter then cuts each piece relative to this point. The origin is setfrom the beam control panel or at the operator workstation (see chapter 3). Theorigin light is a red laser light located in the cutter head that shines on the cuttingtable (see the Safety chapter at the beginning of this manual).

WARNING! The origin light uses a Class IIIa laser. Do not lookdirectly into the laser beam without protective glasses. Do notplace any reflective (shiny) material on the cutting table.Remove watches, rings, and other jewelry. Reflected laser lightmay cause eye injury.

X0, Y0


The origin must be close enough to the lower left corner of the table so that themarker can fit on the table. For example, the origin shown below is at X25, Y50.

With that origin, the marker extends off the table in the Y direction. You cancorrect this situation by moving the origin to X25, Y25.

If the cutter cannot cut the marker because it will go off the table, you willreceive an off table message, such as one of the following:

Off table in +Y

Off table in -X


Using the Check Origin feature, the system automatically verifies that themarker will fit on the cutting table with the current origin. It does this beforecutting the marker. If the origin will not work for your marker, the systemdisplays an error message like this:

Bad Origin: X too high (x.xxx)acceptable range: x.xxx - x.xxx

where x.xxx is a table location in the X direction. You get a similar message ifthe origin needs to be corrected in the Y direction.

Bite Feeding

TCW and ZVC systems use a conveyor for bite feeding. Bite feeding is a featurethat matches cutter head movement with conveyor movement, permittingautomatic cutting of a long spread. The GERBERcutter does this by cutting thespread in sections. The marking system sets the length of each section in inchesor centimeters as one bite. After the cutter pulls the bite onto the cutting tableand cuts it, the conveyor automatically advances, positioning the next bite on thecutting surface.

An example of how the conveyor and bite feeding work is shown on the nextpage.

Diagram 1 shows a 48.8 m (160 ft.) spread of material that the marker makerhas divided into 20 bites, each 2.4 m (8 ft.).

To begin automatic cutting, the conveyor pulls the leading edge of the spreadonto the cutting surface with the aid of underlay paper. The conveyor movesuntil it pulls the first bite onto the cutting table as shown in Diagram 2.

The GERBERcutter cuts the first bite, including pieces that extend into thesecond bite As shown in Diagram 3. The knife cuts a slit in the selvage of thematerial to mark the origin of the second bite. The slit (or edge clip) made by themarking system is a reference point in case you stop cutting during the secondbite.


Next, the conveyor automatically moves the first bite down the cutting table andbrings the second bite in position to be cut as shown in Diagram 4. While thebundle handlers are removing the pieces from the first bite, the GERBERcutterbegins cutting the second bite.

After the system completes the second bite, the conveyor moves the third biteonto the cutting surface. It brings the second bite down to the bundle handlers,and moves the first bite scrap from the cutting surface to the take–off table,where you can collect or discard it as shown in Diagram 5.

The GERBERcutter keeps feeding bite after bite until it cuts the whole spread.


Software and Files

Software

Software is the set of computer programs that the C200 controller uses to run theGERBERcutter and communicate with you. These programs include:

• C200MT — Cutter control software that reads cut files and setups to tellthe cutting table how to cut material; this program starts upautomatically when you power on the GERBERcutter.

• Windows NT — Operating system for the PC at the operatorworkstation.

For more information about C200MT software and Windows NT, refer to theC200MT Software User's Guide.

Cut File

A cut file is a computer data file that tells the GERBERcutter how to cut a set ofpatterns (a marker) out of a spread of material. The cut file is generated by aGGT marker making system such as the AccuMark or MicroMark.

Setup

A setup is a computer data file that sets up the system for the materials beingcut. For example, you may have one setup for cutting denim and another forflannel. The C200MT software comes with several default setup files. Seechapter 4.

Note: Setups were previously called Configuration or Config files.

Chapter 3 Cutting Markers Page 27

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Sections in this chapter explain:

• Spreading material.

• Basic cutting on your GERBERcutter.

• Beyond the basics.

• Recovery after an EStop or system power down.

For additional information on how to use C200MT program features, refer to theC200MT Software User’s Guide.


Spreading Material

CAUTION: Different materials require specific spreading methods for the bestcutting results. Also, Static systems have different spreadingrequirements than TCW and ZVC systems which have conveyorizedtables. The following procedures are general guidelines only.

To spread material on the spreading table

1. Place an underlay of perforated or air–porous paper (25 to 60 lbs.) onthe spreading table. Be sure the paper is straight on the table andextends at least 0.3 m (1 ft.) beyond the leading edge of the spread. ForStatic systems this should extend approximately 1 m (or 3 ft.) beyond.

The underlay lets you move the spread without pulling or disturbingthe material. When vacuum is applied, the underlay keeps the materialclean and in place. It also provides extra support for stretchy andlightweight material.

2. Using the method appropriate for your site, spread the material on topof the perforated paper. Normally the straight edge is on the operator’sside of the cutting table.

CAUTION: Do not exceed your GERBERcutter’s maximumcompressed material ply height — 7.6 cm (3.0 in.).Exceeding the maximum material ply height will lowercut quality, shorten knife life, and may damage yourGERBERcutter.

3. If you use full–size plots to identify individual pieces after they are cut,put the correct one on top of the spread.


Basic Cutting

The following sections explain the basic steps, shown in the diagram below,required to a cut a marker on a GERBERcutter.

5. Select setup

At CutterAt OperatorWorkstation

1. Turn on cutter

6. Open marker

7. Turn on vacuum

13. Start processingmarker

14. Recovery(if needed)

2. Enableservo power

3. Initialize cutter

8. Turn on laser

9. Positionlaser light

4. Position first bite

10.Set marker origin

11. Selectcutting speed

12. Turn onknife motor


WARNING! Read the safety precautions at the beginning of this manualbefore performing any operation at the cutter.

Turning on the Cutter

Turning on, or powering up, the cutter automatically opens Windows NT andruns the C200MT program at the operator workstation.

To turn on the cutter

1. Make sure that no limit switch is parked on its magnet (see chapter 1).If necessary, manually move the cutter head or beam toward the centerof the work surface.

2. At the beam control panel, set:

a) Knife button to OFF.

b) Feed rate to a low speed, such as 2 or 3.

3. For TCW systems, turn on the table power circuit breaker(approximate location shown below). For Static and ZVC systems, turnon circuit breakers at the panels for the external vacuum and for tablepower or the lay puller.

Table Power(not shown)

C200 Controller


4. Turn on circuit breaker 1 for the C200 controller. The control panel islocated on the right side of TCW systems; for other S91 cutters, theC200 control panel may be located on a nearby table.

Enabling Servo Power

Pressing the Servo Power Enable button turns on power to the servo motors.These motors control movement of the cutter head and beam during cutprocessing.

To enable servo power

1. Make sure that cutter power is turned on and the C200MT program isrunning.

2. At the operator workstation, press the Servo Power Enable button.

The servo motors are turned on and gauges display across the top of theC200MT Main Cutter Control screen.

3. If nothing happens when you press the Servo Power Enable button, doall of the following:

− Make sure that no limit switch is parked on a magnet.If necessary, manually move the cutter head or beam toward thecenter of the work surface.

− Make sure all EStop switches are up; if not, twist clockwise.

− Make sure no EStop plunger is activated.

Circuit Breaker 1


Initializing the Cutter

Initializing the cutter identifies the zero position for the table in X and Y. This isalso called the home position and is written as (0,0). Limit switches (see chapter1) tell the C200MT program when the cutter head reaches the (0,0) position.

Note: You must initialize the cutter before processing markers. Otherwise,an error message displays.

To initialize the cutter

1. Make sure that the cutter power is turned on and the servo power isenabled.

2. Do one of the following:

− Press the Initialize button on the beam control panel.

− Press the Initialize key on the keyboard.

The cutter head and beam moves to the (0,0) position on the table. Anew origin is reported in the System Messages box.

Note: If the cutter is set up for the Right Side Option, the cutterhead and beam moves to the right side of the table.


Positioning the First Bite

After the cutter is initialized, use the jog switch at the take–on end of the cutterto advance the spread (material) into cutting position.

On TCW and ZVC Systems

These systems use a conveyor to jog, or move, the spread into position on thecutting table. TCW systems also use the clamp bar to help the conveyor movethe spread.

To position the first bite

1. Manually pull about 1 m (3 ft.) of the spread onto the cutting table.

2. Use the jog control switch to advance the conveyor until the spread isabout 25 cm (10 in.) from the take–off end of the cutting table.

CAUTION: Do not advance the conveyor too far. You can notreverse the conveyor without disturbing the spread.

3. Manually pull the plastic film overlay (polyethylene) from the filmdispenser to cover the entire bristle surface. This allows proper vacuumcompression.

CAUTION: If not positioned carefully, the plastic film can getcaught in the racks along which the beam travels. Toavoid damage to material and your GERBERcutter, keepthe plastic film away from the racks.

On Static Systems

Static systems use a motorized lay puller to move the spread into position on thecutting table.

To position the first bite

1. The tow bar assembly of the motorized lay puller must be located at thespreading table. If not, return it to this position.

2. Wrap the 1 m (3 ft.) extended end of underlay paper up over thespread. See the Spreading Material section in this chapter.


3. Manually pull the spread and underlay paper onto the lower portion ofthe tow bar assembly. Initiate clamping to lower the upper portion ofthe tow bar assembly.

4. At the cutting table, turn on the motorized lay puller. The tow bar ispulled along the cutting table.

5. When the spread covers the length of the cutting table, turn off themotorized lay puller. Raise the upper portion of the tow bar assemblyand position the end of the spread flat on the table.

The tow bar waits at this end of the table until all pieces are cut andremoved from the table.

8. Manually pull the plastic film overlay (polyethylene) from the filmdispenser to cover the entire bristle surface. This allows proper vacuumcompression.

CAUTION: If not positioned carefully, the plastic film can getcaught in the racks along which the beam travels. Toavoid damage to material and your GERBERcutter, keepthe plastic film away from the racks.


Selecting a Setup

The C200MT program includes default, or preset setups, that configure thesystem for most cutting applications. A setup is a file containing parameterswhich enable or disable various features, options, and modes. Preset setups arebased on characteristics of the spread. For information on customizing setups,refer to the C200MT Software User’s Guide.

To select a setup


− Press the Settings key on the keyboard.

− From the Setup menu, select Settings.

2. If some other page is selected, click the Setup List tab.

3. Use the pointing device to select the Name of the setup you want.

Note: To enter or edit a description for the setup you just selected,click in the field at the bottom of the page and type a newdescription.

4. To select this setup as the current setup, click the Apply or the OKbutton.

5. When prompted to Activate the selected Setup, check your changesand then click the Yes button.

6. When satisfied with the changes, press Enter or click the OK button.

Your system is now configured.


Opening a Marker

Use the Marker Open feature to select a marker, or cut file, and open it forprocessing. The default directory for markers is C:\USER. To change the defaultdirectory, refer to the C200MT Software User’s Guide.

To open a marker


− Press the Open Marker key on the keyboard.

− From the Marker menu, select Open.

2. If you know the name of the marker you want to open, type the name inthe Marker Select dialog box. Press Enter or click the OK button. Goto step 6.

OR

To view a list of available markers on the hard disk, network, or diskdrive(s), press Enter or click the OK button. The Marker Open screendisplays.

Note: For a Right Side Option cutter, you will be prompted to entera new marker width. Press Enter to accept the marker widthor type a new marker width and then press Enter.

3. To change drives and directories, use the pointing device, Tab key, orArrow keys to select a drive and then a directory.

Note: To view files on a different 3.5 inch or 5.25 inch disk, insertthe new disk and click the Rescan Drives button.

4. Select the marker you want to process.

5. Press Enter or click the OK button to return to the C200MT MainCutter Control screen.

6. The first bite of the selected marker is processed and displays in theMarker Plot screen. Verify that this is the marker you want to cut.


Turning on the Vacuum

Use the Vacuum feature to turn on the table vacuum in order to process markers.When finished cutting, you can repeat the following procedure to turn off thetable vacuum. For information about setting vacuum features, refer to theC200MT Software User’s Guide.

To turn the vacuum on in order to cut

1. Make sure that the first bite is positioned on the table and the correctmarker is open.


− Press the Vacuum On/Off button on the beam control panel.

− Press the Vacuum key on the keyboard.

Turning on the Laser Light

The laser origin light is turned on by pressing a button located on the cutterhead. This light is used to visually locate the marker origin on the cutting table.

WARNING! The origin light uses a Class IIIa laser product. To avoid injury toyour eyes, do not look at the laser at any time. Also, do not place anyreflective material, such as mirrors, polished steel, or jewelry on thecutting table.


Setting the Marker Origin

Use the Origin feature to establish the origin, or X,Y position, for a marker.

To set the marker origin

1. At the beam control panel, make sure the Feedrate dial is set to 1or 2.

2. Press and hold the Slew Enable button.

3. Use the joystick and then press the Arrow buttons to move the cutterhead until the laser origin light falls on the lower left corner of thespread.

4. Release the Slew Enable button.


− Press the Origin button on the beam control panel.

− Press the Origin key on the keyboard.

The origin is reported in the System Messages box, where x.xxx andy.yyy are the absolute table coordinates (origin) for the lower leftcorner of the marker.

Note: If you use Fabric Alignment to adjust for a spread that is notstraight on the cutting table, do so now. See the BeyondBasics section later in this chapter.


Selecting Cutting Speed

To select cutting speed

1. At the beam control panel, use the Feedrate dial to select theappropriate cutting speed for processing the open marker.

This speed depends on the material being cut; 5 is a good startingspeed.

2. To manually adjust cutting speed, use the Feedrate dial, as needed,throughout the marker.

OR

Cutting speed can be automatically adjusted, for example when cuttingcorners, by parameter settings in the Setup file. Refer the C200MTSoftware User’s Guide.

Turning on the Knife Motor

WARNING! The knife blade is very sharp. Be extremely careful whenworking near the knife blade. See the Safety Precautionschapter at the front of this manual.

To turn on the knife motor

At the beam control panel, use the Knife switch to turn on theknife motor.

The knife reciprocates (moves up and down).


Processing a Marker

Use the Start feature to begin processing, or cutting, a marker.

To start processing a marker:

1. Make sure you have completed all the procedures previously explainedin this chapter.

WARNING! Check that it is safe to begin cutting! Make surenobody is near the cutter head, beam, and conveyor.


− Press the Start button on the beam control panel.

− Press the Start key on the keyboard.

The piece being cut is outlined in the Marker Plot screen and thecurrent piece and bite number display in the System Status window.

3. When prompted that processing is complete, press Enter or click theOK button.


Exiting the Program

This section gives the steps necessary to close the C200MT program and shutdown the cutter.

CAUTION: To avoid losing data, always quit the C200MT program beforeshutting down Windows NT. Also, shutdown Windows NTbefore turning off the main circuit breaker for the cutter.

To quit the C200MT program

1. Make sure that the cutter is idle (not processing data).

2. From the Quit menu, select Confirm .

To shut down the cutter

1. From Windows NT, do one of the following:

− From the File menu, select Shutdown. Or, press ALT + F4.

− Click the Start button and then click Shutdown.

2. In the Shutdown dialog box, click the radio button next to Shutdown.Then press Enter or click the OK button.

3. When prompted that it is safe to turn off your computer, turn off thecircuit breaker for the C200 controller.

4. For TCW systems, turn off Table power. For Static and ZVC systems,turn off power at the panels for the external vacuum and for tablepower or the lay puller.


Beyond the Basics

Besides allowing you to cut a marker using the basic steps, the C200MTprogram provides commands and parameters for specific cutting applications.This section explains how to use:

• Fabric Alignment.

• Pause Between Bites.

• Data Scale Factor.

• Trim Cut.

• Move to Origin.

For more information on parameters, refer to the C200MT Software User’sGuide.

Using Fabric Alignment

Fabric Alignment can be used to cut a spread that is skewed relative to thecutting table. This is done by selecting two points along the length of the spreadto define an adjustment angle. Use with Pause Between Bites (see next section).

To cut a skewed spread

1. Make sure that the Check Origin parameter in the Options and Modescategory is turned off.

2. Set the origin for the marker.

3. To define a new angle:

WARNING! Check that it is safe to move the cutter head andbeam! Make sure nobody is near the cutter head, beam,and conveyor.

a) At the beam control panel, press and hold the Slew Enable button.

b) Use the joystick and Arrow keys to slew the laser origin light to apoint along the spread that is the same distance in Y from the edgeof the marker as the origin.

c) Release the Slew Enable button.

d) Press the F2 button twice.


4. To use the previous angle:

a) From the Cutter menu, select Fabric Alignment.

b) Click the Recall button on–screen.

5. Between each bite, repeat step 3 or 4 as needed.

Using Pause Between Bites

It is possible to stop the cutter between bites in order to perform a procedure,such as setting origin or fabric alignment.

To use pause between bites

1. Edit the setup using Parameter Manager and the Bite Parameterscategory. Refer to the C200MT Software User’s Guide.

The cutter will pause automatically between each bite.

2. When cutting stops, complete any necessary procedure.

3. Process the next bite.

Using Check Origin

Check Origin can be used to check whether or not the entire marker will fit onthe usable table surface based on the current origin. For example, if the X valueof the origin is too great, pieces at the take–on end of the current bite might notcut properly.

To check the origin

1. Edit the setup using Parameter Manager and the Options and Modescategory. Refer to the C200MT Software User’s Guide.

2. Open and set the origin for a marker as usual.

3. If pressing the Start button results in a system prompt of Bad Origin :

a) Reposition the cutter head within the acceptable range, asprompted.

b) Set the Origin and press the Start button again.


Using X Data Scale Factor, Y Data Scale Factor

On occasion you may need to adjust scaling for cut file data so that a marker willfit on the available material. Scaling can be adjusted in either X, Y, or both Xand Y directions.

To use a data scale factor

1. Calculate the X data scale factor by dividing the usable material lengthby the marker length.

2. Calculate the Y data scale factor by dividing the usable material widthby the marker width.

3. Edit the setup using Parameter Manager and the Data Format/Scalingand RSO category.

4. Open and process the marker.

CAUTION: To avoid cutting the next marker incorrectly, return each datascale factor to 100% after cutting the current marker.

Using Move To Origin

Use the Move to Origin feature to move the cutter head to the last establishedorigin. You can use this command whenever you want to verify the origin; forexample, use after Fabric Alignment.

To move to the last established origin


− Press the Move to Origin key on the keyboard.

− From the Cutter menu, select Move to Origin.

The cutter head and beam moves to the last established origin which isreported in the System Messages box.


Using Trim Cut

Use the Trim Cut feature to trim away excess material and plastic after cutting amarker.

To trim


− Press the Trim Cut button on the beam control panel.

− From the Cutter menu, select Trim Cut .

2. At the beam control panel, use the slew keys to make required cut(s).

3. To exit Trim Cut mode, do one of the following:

− At the beam control panel, press the Stop button.

− At the operator workstation, press Esc.


Recover y from Interrupted Cutting

Recovery procedures allow the cutter to resume cutting after a power loss,EStop, or a system power down interrupts cut processing. An EStop occurswhenever cutter motion is stopped by pressing one of the emergency stop(EStop) switches or plungers located on the cutter.

Note: The reason for the power down displays as an on–screen errormessage.

Recovery procedures include:

• Restore State — Return to the last piece and bite being cut.

• Restore Origin — Restore origin for the current marker.

• Bite Search — Find and cut a specific bite.

• Piece Search — Find and cut a specific piece.

• Piece Recut — Recut a specific piece.

Before Using Reco very Commands

Before using any of the recovery commands you need to perform the followingprocedures.

To correct the condition before recovery

1. If the operator workstation lost power, turn on the main power supplyand start up the C200MT program. Then enable servo power andinitialize the cutter.

OR

If an EStop occurred, press Enter to clear the message from the screen.Enable servo power.

OR

If accidental system power down occurred, press Enter to clear anyerror message from the screen. Restart Windows NT, if necessary, andrestart the C200MT program. Then enable servo power and initializethe cutter.


Using Restore State

Use the Restore State feature to return to the last piece and bite that was beingcut before a power loss, EStop, or system power down. This featureautomatically restores all of the following:

• Reopens the cut file.

• Restores the setup.

• Restores Fabric Alignment.

• Restores the origin.

• Restores the bite (TCW or ZVC systems).

• Searches for the piece being cut before the cutter stopped.

• Restores a Job Queue (see chapter 4).

To restore state of last marker

1. Make sure that the condition which stopped cutting is corrected.


− Press the Restore State key on the keyboard.

− From the Recover menu, select Restore State.

3. If the marker and piece information displayed in the Restore Statedialog box is correct, press Enter or click the OK button.

Note: If this information is not correct, you can use the procedurefor restoring state manually. See the next section.

The marker is opened and the System Message box prompts that theState is restored.

4. Verify that the correct piece and bite number display in the SystemStatus window. If correct, start processing.


Restoring State Manually

Instead of using the Restore State feature, you can manually restore state usingthe following steps.

To restore state manually

1. To set the origin, do one of the following:

− Position the origin light at the top of the bite clip for the last bitecut. Set a new origin.

− If restoring the first bite (TCW or ZVC), use the origin or setorigin as normal.

2. Choose the correct setup to configure your cutter.

3. Open the marker.

4. Use Piece Search explained in the next section.


Using Piece Search

Use the Piece Search feature to find and cut a specific piece in a marker. This isuseful after an EStop or system power down, especially if the Restore Statecommand does not find the correct piece to cut.

To find and cut a specific piece

1. If cutting was interrupted, make sure that the condition is corrected andthe marker you want to cut is open.


− Press the Piece Search key on the keyboard.

− From the Recover menu, select Piece Search.

3. In the Piece Search dialog box, type to enter the Piece to Search to.Then press Enter or click the OK button.

The Marker Plot screen shows the piece in the marker. The SystemMessages box reports that the requested piece was found and gives thebite number it was found in (TCW and ZVC systems).

Note: When the piece being searched for is split across two bites, adialog box displays. If you want to begin cutting the part ofthe piece located in the first of these two bites, click the Yesbutton. If not, click the No button.

Using Piece Recut

Use the Piece Recut feature to recut a specific piece in a marker that might nothave been cut properly.

To recut a specific piece

1. Make sure the marker you want to cut is open.

2. From the Recover menu, select Piece Recut.


3. In the Piece Recut dialog box, type the piece number to recut. Thenpress Enter or click the OK button.

The piece you want to recut displays alone in the Marker Plot screen.The System Status window reports that the requested piece was foundand gives the bite number it was found in (TCW and ZVC systems).

4. Position material on the table.

5. Position the cutter head near the lower left corner of the area to be cut.

6. Set the origin.

7. Start processing.

Using Restore Origin

Use the Restore Origin feature to restore the origin point.

To restore the last origin

1. Make sure that the condition which stopped cutting is corrected.

2. From the Recover menu, select Restore Origin.

The origin is reported in the System Messages box, where x.xxx andy.yyy are the absolute table coordinates for the restored origin point.

Using Bite Search

For TCW and ZVC systems, use the Bite Search feature to find and cut aspecific bite in a marker.

To find and cut a specific bite

1. If cutting was interrupted, make sure that the condition is corrected andthe marker you want to cut is open.

2. From the Recover menu, select Bite Search.

3. In the Bite Search dialog box, type to enter the Bite to Search to. PressEnter or click the OK button.

The System Messages box reports that the requested bite is found andgives the piece number of the first piece in that bite.

Chapter 4 Utilities Page 51

4�8WLOLWLHV�8WLOLWLHV

This chapter presents a brief overview of the following C200MT utilities:

• Parameter Manager — Customizes setups by editing parameter settings.

• Run Time Biting — Bites markers for cutting.

• PreProcessor — Preprocesses cut file data to reduce cutting time andmaterial waste when cutting the marker.

• View Marker — Displays pieces and bites in a marker and plays backhow the marker will cut.

• Queue Manager — Creates and edits job queues for processing a selectbatch of markers.

• File Manager — Manages marker files, performing such tasks ascopying, moving, renaming, and deleting.

• CIDB — Generates reports about markers processed on aGERBERcutter.

Chapter 4 Utilities

Parameter Manager

The Parameter Manager allows you to:

• Change parameters for one or all setups, temporarily, or permanently.

• Create a new setup.

• Change the current setup.

• Print the current setup.

• Search for a specific parameter.

• Assign access levels to parameters.

• Customize the Frequently Used Parameters category for your needs.

For information on using the Parameter Manager, refer to the C200MT SoftwareUser’s Guide.

Access Levels by Password

Access to specific parameters can be restricted in order to prevent accidentalchanges. The C200MT program allows for four levels of access to the ParameterManager.

• User.

• Supervisor (password required).

• Field Service (password required).

• Software (password required).

Parameters and Categories

Parameters are settings that are included in the setup for your cutter. Someparameters turn a feature on or off. Other parameters define a value within anallowable range.

Categories group parameters that relate to a cutter feature. See the table on thefollowing page.


Categories that can be accessed at the user level are listed in the table below. ForField Service level parameters and information about individual parameters,refer to the C200MT Software User’s Guide.

Category Parameters Used To

Frequently Used Parameters Provide quick access to frequently used parameters; this category canbe customized.

Knife and Drill Speeds Control knife and drill speed for specific cutting conditions.

Sharpen Parameters Control how and when the knife is sharpened.Define how the cutter determines wear on the knife blade and when theknife should be replaced.

Cutting Parameters Control advance and overcut distances and limits.Control cut angle and slowdown percentage for cutting operations.

Vacuum System Control the vacuum options.

Ignore Codes Tell the cutter to ignore or respond to certain marker data codes.

Bristle Cleaner Control times and number of sweeps for automatic cleaning.

Knife and Path Intelligence Control how Knife Intelligence compensates for cutting forces onthe knife.Set up Path Intelligence to automatically adjust feed rate for the bestcut quality and throughput.

Data Format/Scaling and RSO Define the format of cut file data or AAMA data conversion.Define X and Y–axis scaling.Define marker size.Initialize RSO cutters.

Bite Parameters Define how the cutter handles bites. Define end park position.(TCW and ZVC systems)

Options and Modes Turn on/off various GERBERcutter features.

Mirror Image and ClippingWindow

Turn on the mirroring options which rotate the marker before cutting.Turn on the clipping window feature and define boundaries.

OPSTOP and Report Options Control how the cutter responds to Opstop codes.Define Cutter Info Database (CIDB) reporting.

Selvage Cut/Contiguous Cut Control Selvage/Web cutting for vertical line cuts through the selvageor the selvage and web.Control processing of consecutive markers.

System Setup Parameters Set maximum beam velocities for dry haul and cutting.Check system setup parameters set by field service.

Queue Manager Set preferences for handling cut files and job queues in QueueManager.

Cut File Preprocessor Set parameters for the Preprocess utility.

Chapter 4 Utilities

Run Time Biting

For TCW and ZVC systems, the Run Time Biting utility bites the marker,designating sections of the marker for automatic cutting. Each bite fits on thecutter table and can be cut at one time. Run Time Biting can take place eitherwhile:

• Cutting a marker.

• Preprocessing a marker with Bite Generation (see PreProcessor sectionin this chapter).

Settings for Bite Parameters determine the length of the bites and whether theyare equal (static length biting) or variable in length (variable length biting).

For diagrams showing biting, see chapter 2. Also, refer to the C200MT SoftwareUser’s Guide.

Static Length Biting

Static length biting divides the marker into bites of equal lengths. If a pieceextends beyond the bite, the cutter splits the piece and only cuts the portion ofthe piece that fits within the bite. When the cutter has finished cutting all piecesor parts of pieces for that bite, the conveyor advances the next bite. The cutterthen cuts the second portion of the piece.

Variable Length Biting

When Variable Length Biting is turned on, the cutter only splits those pieces toolarge to fit on the cutting table. This feature is useful to:

• Eliminate split pieces in a marker requiring pieces not be split.

• When matching plaids and stripes in split pieces.

Using Variable Length Biting, the cutter cuts all pieces in a given bite thatcompletely fit on the table. The conveyor then advances to the uncut piecefarthest to the left. It cuts that piece and any other whole pieces on the cuttingtable. The conveyor again advances to the uncut piece farthest to the left. Thisstep is repeated until all pieces are cut. Variable length bites usually are shorterand occur more often than static length bites.


PreProcessor

Use the PreProcessor utility to process and organize cut file data in order toreduce cutting time and material waste when cutting the marker. Withoutpreprocessing, all lines for each piece in a marker are cut before the next piece iscut. The PreProcessor utility optimizes on the normal cutting strategy by usingbite generation and features from the GGT POWER Processor™ program:

• Bite Generation — Generates bite data before preprocessing (see theRun Time Biting section on the previous page).

• Reorder — Resequences the order in which pieces will be cut in amarker.

• Common Line — Cuts common lines only once.

• Path Optimization — Cuts pieces more efficiently.

For information on using PreProcessor, refer to the C200MT Software User’sGuide.

Reorder

Reorder allows the system to automatically determine the sequence in whichmarker pieces are cut based on parameters that you can define or change.

Common Line

Common Line analyzes and reorganizes cut files so that all common lines arecut once. A common line is a line that is shared by two neighboring pieces in amarker or cut file. This feature can save cutting time and improve cut quality incommon line regions when cutting markers with block–shaped pieces.

Path Optimization

Path Optimization analyzes pieces in a cut file and looks for more efficient waysto cut them. For example, four neighboring pieces, semicircular in shape, mightbe cut as a “figure 8.”

Chapter 4 Utilities

View Marker

Use the View Marker utility to access the GGT Cutview screen. Features in theCutview screen allow you to:

• View a marker.

• Change the view scale.

• Overlay a grid.

• Display dry haul lines, bite lines, drill points, and data points.

• Change default colors.

• Playback on–screen how the cutter is going to cut the marker, piece bypiece.

For information on using View Marker, refer to the C200MT Software User’sGuide.

Selecting Pieces

To select a piece, first click the Piece Select button and then click inside thepiece that you want to playback or get information about. Information about thecut data for the piece displays on–screen in the Piece Data window.

Tool Code Reference

Use the Tool Code Reference command in the Cutview Help menu to find adescription and example of the tool codes that may display in the Piece Datawindow.

Playing Back a Marker

Cutview provides three options for playing back cut data in a marker.

Animate

Use to playback a marker, cutting pieces according to piece number sequence.

Piece by Piece

Use to switch playback modes so that cut data displays one piece at a time,beginning with a selected piece.

Segment by Segment

Use to switch playback modes so that cut data for a selected piece is displayedone line segment at a time.


Queue Manager

When processing a batch of markers, use the Queue Manager utility to:

• Create a job queue.

• Run a job queue.

• Close a job queue.

• Select the next job in a queue.

• Edit a job queue.

Queue Manager runs minimized (an icon or task bar button displays at thebottom of the screen) while the C200MT is running a queue.

For information on using the Queue Manager, refer to the C200MT SoftwareUser’s Guide.

Job Queues

A job queue contains multiple markers to be cut sequentially. Each marker andthe corresponding setup file are called a job. Each job is opened, processed, andclosed automatically until all jobs have been processed.

Using job queues can increase throughput because queues can be created whileother markers are being processed and then run automatically. More than onejob queue window can be open at a time in the Queue Manager screen.

Defaults for Queue Manager

To simplify creating and editing a job queue, the Queue Manager uses thefollowing default files and directories:

• Location of available markers — C:\USER

• Setup to use when adding a job — DEFAULT.CNF

Queue Manager defaults can be changed using the Change Defaults command inthe Tools menu of the Queue Manager screen.

Chapter 4 Utilities

File Manager

Managing cut files is an important task. You can use the File Manager utility toperform the following routine data management tasks:

• Copy files from a disk or a network drive to the hard drive of the cutter.

• Move files to another directory on the hard drive.

• Rename files from a previous season.

• Delete files after backing them up to disk or to the network.

• Manage directories.

Note: If you are familiar with Windows NT 3.51 or Windows 3.1File Manager, you already know how to use features in theC200MT File Manager. For those learning how to useWindows, refer to the C200MT Software User’s Guide orrefer to your Windows documentation for additionalinformation.

Directories and Files

Directories and sub–directories help organize cut files, for example by style orseason. Use the File Manager utility to create or delete directories.

File Manager uses a window to display information about the directories andfiles for each drive. More than one drive window can be open at a time. At theleft of the drive window is a directory tree showing all directories on that drive.Click on a directory to display all files for that directory.

Using Paths to Locate Files

When managing marker files, you may find it easier to type the path to locate afile rather than making selections with the pointing device. A path is all theinformation (drive, directory, and any sub–directory) the system requires tolocate a directory or file. Items in the path are separated by the backslash (\).

For example, to select files in the sub-directory SLACKS in the WINTERdirectory on the network H drive, type H:\WINTER\SLACKS.


Using Wild Cards to Locate Files

Using a wild card can simplify managing multiple files. Wild cards replacesimilar character(s) in a file name, so that the system considers them the samefile. The “?” wild card replaces one character in a file name; the “*” wild cardreplaces several characters.

For example, to move files named SUIT123, SUIT456, and SUITABC,type SUIT*

Locking File Manager

The File Manager is password protected. The first time the File Managercommand is selected during a C200MT session, the supervisor password mustbe entered. File Manager can then be used for the remainder of the C200MTsession or until it is locked again.

Refer to the C200MT Software User’s Guide for more information and thedefault passwords.

Chapter 4 Utilities

Cutter Information Database (CIDB)

CIDB is an optional database utility which can be used to generate reports forthe C200MT program. When this option is enabled, the system automaticallyinserts information about the marker currently being processed into the CutterInfo database. Reports based on this data can:

• Be viewed and printed from the C200MT program.

• Be output automatically to a text file in the C:\REPORT directory.

• Be accessed using a database program.

• Include operator comments.

CIDB reports can be viewed on–screen using the Report Generator. Forinformation on using CIDB, refer to the C200MT Software User’s Guide.

Marker Report Types

The following types of Marker reports are available:

• Partial Marker reports.

• Marker reports.

• Shift reports.

Partial Marker Report

Partial Marker reports are permanent entries in the CIDB database which can bemade before a marker is completely cut. A partial marker report can be:

• Used to obtain CIDB statistics for cutting that has occurred up to thepresent, for example, when a shift ends.

• Requested for any marker that is currently being processed, as long ascutting has not finished.


Marker Reports

For each cut file processed on a GERBERcutter with the CIDB option, markerreports are automatically entered in the CIDB database. These reports can beviewed and printed using the Report Generator. Marker reports can also be sentto a text file, MARKERS.RPT. Marker reports include:

• Prep time (for example, time spent setting the marker origin or opening acut file).

• Interrupt time (when the cutter is stopped using the Stop button).

• Sharpen time.

• Bite time.

• Downtime (when the C200MT program is not running).

Shift Reports

Shift reports are summary reports derived from individual marker report timesfor the shift. These reports can be viewed and printed using the ReportGenerator. A Shift report includes:

• Interrupt time (when the cutter is stopped using the Stop button).

• Downtime (when the C200MT program is not running).

• Percent of operating time and percent of total time for all times reported.

• Distance totals for the shift as well as their percentage of total distance.

• Average cut speed and throughput for the shift.

• Miscellaneous statistics (for example, knife wear and free disk space).

• Operator comments.

• System comments (includes all cutter error messages).

Chapter 4 Utilities

Chapter 5 Optimizing Cutter Performance Page 63

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Differences in fabric and spreads require that adjustments be made to the cutter.This chapter covers procedures that help keep your GERBERcutter running atpeak performance. These include:

• Sharpening and replacing the knife.

• Setting defaults for knife speeds.

• Using Knife Intelligence to compensate for lateral force on the knife.

• Using Path Intelligence to automatically control cutter speed based onknife sharpness, vacuum level, and XY force.

• Controlling vacuum levels.

Note: Setups allow you to set adjustments specifically for differences infabrics and spreads. For more information about availableparameters, refer to the C200MT Software User’s Guide.

Sharpening and Replacing the Knife

The knife blade must be sharp and within wear limits to cut properly. C200MTfeatures provide:

• Automatic sharpening cycles while cutting.

• Sharpening when the cutter is idle.

• Sharpening when installing a new knife.

• Resetting default knife speeds.

WARNING! The knife blade is ver y sharp. See chapter 6 for specificprocedures to inspect, adjust, remove, and install a knife blade.


Automatic Sharpening

The GERBERcutter provides automatic sharpening cycles which occur while amarker is being cut. Automatic sharpening is controlled by Sharpen parametersettings in the setup. For example, how often a sharpen cycle occurs can bebased on cutting distance or piece count.

For specific information, refer to the C200MT Software User’s Guide.

Sharpening When the Cutter is Idle

When the cutter is idle, a sharpen cycle can be initiated manually for the currentknife or a newly–installed knife.

Note: If you are sharpening a newly–installed knife, first use the NewKnife command.

To sharpen when cutter is idle

1. Make sure the knife motor is running.

WARNING! The knife blade is very sharp. See chapter 6 ofthis manual for specific procedures to inspect, adjust,remove, and install a knife blade.


− Press the Sharpen key on the keyboard.

− Press the SHARP button on the beam control panel.

3. In the Sharpen Knife dialog box that displays on–screen, press Enteror click the OK button to accept the defaults for sharpening the currentor a new knife. Or you can enter a different number of sharpens.

When sharpening is finished, the Knife Wear gauge is reset.


Resetting for New Knife

Your cutter uses knife wear logic to track sharpening cycles for the currentknife. This logic, which prompts when the knife wear limit is reached, must beupdated whenever a new or partially–used knife is installed. For informationabout setting Sharpen parameters which affect knife wear logic, refer to theC200MT Software User’s Guide.

To reset for a new knife

1. Carefully install a new or partially–used knife blade.


2. Turn on the knife motor .

3. From the Cutter menu, select New Knife.

4. In the New Knife dialog box, check the appropriate radio button for aBrand New or Used knife. If Used is selected, type the number of timesthis knife was previously sharpened.

5. Press Enter or click the OK button to reset the Knife Wear gauge.

Note: After installing a new knife, perform a sharpening cycle (asdescribed on the previous page) before beginning to cut.


Setting Knife Speeds

The table below briefly explains knife speeds that can be adjusted for the currentsession or set as defaults in the setup.

Knife Speed Type Use to

Idle Set reciprocating speed when the cutter is idle.

Dry Haul/Maximum Set reciprocating speed during dry haul.Set minimum reciprocating speed when cutting.

Cut/Maximum Set maximum reciprocating speed when cutting.

Sharpen Set reciprocating speed during sharpen cycle.

Cut Speed=Maximum Define the relationship between maximum cutting speed andthe cutting speed dial on the beam control panel.

To set knife speed defaults, use the Set Knife Speed feature in C200MT. Referto the C200MT Software User’s Guide.

Note: Make sure that the cutter is in the mode for which you want to setknife speed. For example, the cutter must be at idle to set Idle Knifespeed.


Using Knife Intelligence

Knife Intelligence (KI) optimizes cutting performance by:

• Sensing deflection of the knife (lateral force) caused by cutting difficultmaterials or high ply spreads.

• Changing knife angle to compensate for this deflection.

Setup parameters in the Knife and Path Intelligence category define KnifeIntelligence for GERBERcutters. Refer to the C200MT Software User’s Guide.

Knife Intelligence features available in the C200MT program are brieflydescribed below and on the next page.

KI Settings

Use the Knife Settings command in the Cutter menu to quickly adjust thefollowing parameter settings used to compensate for knife deflection:

• KI: Gain — Controls the amount of force which can be used.

• KI: Deflection Angle — Sets the greatest angle allowable for KI to turnthe C–axis.

Nulling Knife Intelligence Sensor

Use the Null KI command in the Cutter menu to reset (to zero) KnifeIntelligence sensor. This command should be used:

• When KI is first turned on.

• Daily after the cutter is initialized (when using KI).

• For each new spread (when using KI).

To null Knife Intelligence

1. Use the slew buttons on the beam control panel to move the cutter headuntil the knife blade is just off the edge of the spread.

2. Turn on the knife motor .

3. Turn on the vacuum .



− From the Cutter menu, select Null KI . In the KI Warning box,press Enter or click the OK button.

− Press the button on the beam control panel twice.


The knife plunges and then rises. The System Messages box promptswhen the Null procedure is completed.

5. As needed the KI Calibration diagnostic (see chapter 7) should be usedat the beginning of each shift to calibrate the Knife Intelligencedeflection voltage sensor.


Using Path Intelligence

Path Intelligence completely or partially controls cut speed using built–inapplication knowledge and by measuring one or more of the following:

• Knife sharpness.

• Vacuum level.

• XY force.

Setup parameters in the Knife and Path Intelligence category define the PathIntelligence (PI) feature. Settings can only be changed when the cutter is idle.Refer to the C200MT Software User’s Guide.

Path Intelligence Diagnostics

The following diagnostics are available to calibrate for Path:

Calibration — Use to set up PI and test the current draw of the cutter head andbeam. This diagnostic should be used at least once daily and for each newspread.

Watch Forces — Use to determine the maximum speed setting and number ofplies to cut.


Controlling Vacuum Levels

Your GERBERcutter uses vacuum to hold material firmly on the table worksurface during cutting. Setup parameters in the Vacuum System category (referto the C200MT Software User’s Guide) define how the cutter:

• Uses vacuum zoning.

• Displays vacuum error warnings.

• Controls vacuum levels and ensures quality cutting; only for cuttersequipped with Vacuum Level Control system.

• Uses the energy savings mode when the cutter is idle.

• Reports low vacuum levels.

Energy Savings Mode

Note: The Energy Savings Mode (ESM) parameter must be enabled. Referto the C200MT Software User’s Guide.

To turn on Energy Savings Mode

1. Make sure the vacuum is turned on.

2. From the Cutter menu, select Energy Savings Mode.

In the main C200MT control screen, the Vacuum Level gauge label ischanged to Energy Savings Mode.

3. Select again to turn off ESM.

S91 Maintenance

Chapter 6 Maintenance Page 71

6�0DLQWHQDQFH�0DLQWHQDQFH

This chapter covers preventive maintenance and corrective maintenanceprocedures for the S91 GERBERcutter. Preventive, or scheduled, maintenanceis important because it improves cut quality and extends machine life. Highlytechnical procedures or those requiring special skills, such as adjustingalignments for the knife and motors, should only be performed by maintenancepersonnel who have received GERBERcutter training. Otherwise, call yourGGT Service Representative.

Use the table below or the index for this manual to quickly find maintenanceprocedures. Illustrations on pages 76 and 77 show assembly locations.

Assembly Subassembly Page Number

Head coverknife drive trainknifesharpener guides and rollerselevatorC–axis yaw alignmentknife drive alignment/speed adjustment

10380, 104106, 17081, 10711080, 86, 11285, 1137980, 86, 97, 11379, 91, 109, 115

Drill drill bitassembly

116, 17181, 87, 92, 97, 118

Beam coversX–axis gearing and belts scale testY–axis roundway and squareway gearing and belt scale test

122

87, 12389, 127

82, 92, 121, 12693, 124, 12889, 127

Table work surface cleanerroundways and racksvacuum filters motor and cover Spencer turbine Hoffman blowerconveyor and clamp barlay pullerresealerplatform and overhead cable

13099, 13282, 133

82, 94, 13493, 98, 13593, 98, 13694, 98, 13689, 95, 99, 13895, 99, 14089, 138100, 102, 141


Safety Precautions

In addition to the safety warnings below, refer to the Safety Precautions chapterat the beginning of this manual.

WARNING! High voltages exist inside the C200 controller,vacuum and platform electrical enclosure and the cutting table.There are no operator–serviceable parts inside. Only qualifiedpersonnel should perform maintenance on these assemblies.Contact your Service Technician in case of a problem. Failureto follow these instructions could cause injury or death.

WARNING! To avoid serious injury, turn off the C200 controller wheninstructed. With the main circuit breaker of the C200 controllerturned on, power is applied to the cutting table and vacuumgenerator. Parts could move suddenly.

WARNING! The origin light on the cutter head uses a Class IIIa laserproduct which points toward the cutting surface. Never lookdirectly into the laser light source; doing so may causetemporary, or even permanent, damage to your eyes. To avoidpotentially harmful reflections, remove all highly–reflectivematerial (such as jewelry) from the cutting surface beforeturning on the origin light. Turn off the origin light beforeperforming any maintenance on the GERBERcutter.

S91 Maintenance


Maintenance Procedures

Basics

The following sections cover basic procedures that need to be performed whilemaintaining a GERBERcutter. These include:

• Removing covers for the head, beam control panel, and end cap.

• Replacing a knife blade.

• Inspecting, cleaning, and lubricating head, beam, and table components.

• Maintaining the table.

• Cleaning filters for vacuum and stack.

WARNING! To prevent injury, turn off the main circuit breaker for the cutterbefore performing maintenance procedures, unless instructedotherwise.

Advanced

CAUTION: To prevent damage to the cutter and/or fabric, only qualified operatorsor maintenance personnel who have received GERBERcutter trainingshould perform the following procedures.

In addition, there are advanced procedures that should only be performed byoperators or maintenance personnel who have received GERBERcutter training.These procedures are indicated by the above caution and include:

• Performing sharpener assembly and presser foot maintenance.

• Checking mechanical alignments, such as heel to heel knife alignmentand that the beam is squared.

• Belt tensioning.

Electrical

Procedures requiring electrical drawings are not covered in this manual.Personnel who have received GERBERcutter training should refer to theappropriate Service Manual or Reference drawings for the cutter.

WARNING! High voltages exist within the vacuum and platformelectrical enclosure and inside the C200 controller. Only qualifiedpersonnel should perform electrical maintenance procedures. Thereare no operator–serviceable parts inside.


General Maintenance

This section provides hints on performing general cleaning and lubrication foryour GERBERcutter.

Cleaning• In general, use a clean rag to wipe old grease, dirt, and lint away.

• Denatured alcohol can be applied sparingly with a rag to removestubborn dirt accumulations. To prevent damage to components made ofrubber or to BRISTLE SQUARES, do not use regular alcohol.

Lubrication• Apply lubricants sparingly with a clean rag.

• Use a stiff paint brush to apply multipurpose grease sparingly.

• Use a grease gun with the appropriate adapter for zerk fittings or aneedle tip where indicated. Fill and then wipe away any excess grease.

CAUTION: Apply all lubricants sparingly. Excess oil or grease candamage fabric. It is better to lubricate lightly and morefrequently than it is to apply one heavy coat.

Lubricant/Cleaner Uses GGT Part No.

GSG–44 Belt pulley, knife guides, knife blade 072395000

Loctite Safety Solvent Sharpener stones 308010101

Petro–Lon Mulitpurpose 596500005

Shell Alvania EP2 Swivel assembly 596500006

Fiske Lubriplate Lithium–based grease 596002003

Chevron SRI–2 Spencer vacuum turbine 596041001

Ordering Spare Parts

If you find a broken or worn part while performing preventive maintenance, youcan order replacement parts through Product Support. For those inside theUnited States and Canada, call GGT Product Support at 800-999-1448. Forthose outside the United States and Canada, please call your local Sales andService office.

Note: The Service Parts CD–ROM is a useful tool for identifying parts andpart numbers. Ask your local Sales and Service office aboutavailability.

S91 Maintenance


Tools Available from GGT

The table below lists tools available from GGT for general maintenanceprocedures for the S91 GERBERcutter. Specific GGT parts or tools required fora procedure are listed at the beginning of that procedure.

Tool Description GGT Part No.

screwdriver set 944211601

socket drive 3/8 in. with 6 in. extension 944582805

crowfoot attachment 3/8 in. x 7/16 in opening 945500000

socket set 1/4 in. and 3/8 in. 944212801

snap ring pliers 90 deg. 944003901

pliers 944003903

wrench 1/4 in. 945500005

wrench 1/2 in. opening 3/16 in. thick 944012502

open end wrench 5/8 in. to 9/16 in. 944012503

hex wrench 1/4 in. 020945000

T-handle hex key set 945500051

right angle handle hex key set 944022402

9-piece open-end combination wrenches 944002401

spanner wrench 021513000

spring scale 945500034

marker pen 608042001

Note: This tool list may vary slightly depending on your systemconfiguration.

Additional Tools

Additional tools required for basic procedures in this chapter:

• Clamping pliers.

• Industrial shop vacuum.

• Ruler.

• Step ladder.

For advanced procedures by personnel with GERBERcutter training:

• Tachometer or strobe light.

• Feeler gauges.


S91 TCW

Surface CleanerAccess Door

ClampBar

BeamControlPanel

OperatorWorkstation

CutterHead

Beam

Take–off End

Resealer

PlatformControlPanel

VacuumFilterDrum

FrontRamp(Take–onCover)

Stack(Mast)

TravelingLight

C200ControllerPanel

End CapCover

ConveyorWorkSurface

BeamFrontRamp

(Take–onCover)

Remote SideTake–on End

ClampBar

Platform DriveWheel

Assembly

RSOPlatform

Panel

Operator Side

S91 Maintenance


S91 StaticFlatPanel

Operator Side

StationaryWorkSurface

EndCap

Cover

OperatorWorkstation

Left End

Remote Side

CutterHead

Beam

S91 ZVC

CutterHead Operator

Workstation

BeamControlPanel

ConveyorWork

Surface

Take–off End

Operator Side

Beam

EndCap

Cover

8 Hour Maintenance Schedule


Maintenance Summary and Schedule

The next sections summarize by assembly the preventive and correctivemaintenance procedures recommended for your GERBERcutter. Checklists foreach maintenance schedule are included in the appendix.


In general, eight hour (per shift) maintenance procedures include:

• Removing lint buildup from and lubricating components.

• Cleaning filters.

• Checking knife alignment.

• Performing knife sharpener maintenance.

WARNING! To avoid serious injury, turn off the C200 controller wheninstructed. With the main circuit breaker for the C200 controller turnedon, power is applied to the vacuum and platform control enclosure andcutting table. Parts could move suddenly.


CAUTION: Excess oil or grease can damage fabric. Apply sparingly.

Head

Check knife yaw alignment

Use the C Home to System Zero diagnostic. See Chapter 7.

Check knife offset alignment

Use the Knife Offset Setup diagnostic. See Chapter 7.

Check knife intelligence alignment

1. Use KI Null. See Chapter 5.

2. Then use KI Calibration diagnostic to calibrate the KI sensor.See Chapter 7.


Page 80 Chapter 6 Maintenance

Fill the tension arm oil cups (a)

1. Turn off power at the C200 controller and open the head cover.

2. Fill each cup with 10 weight synthetic oil.

3. Wipe clean. Lightly apply 10 weight synthetic oil.

Fill the pivot arm oil cup (near b)

Same as above.

Clean and film coat the air cylinder rod (c) for the elevator



Clean and film coat the two elevator guide rods (d)

Same as above.

Head — Knife Drive Train1. Turn off power at the C200 controller and open the head cover.

2. Follow the procedures for removing and inspecting the knife drivetrain beginning on page 104.

Clean and lubricate swivel assembly

1. Use the swivel lube kit to fill the lubrication hole (e) in the swivelassembly with grease. Wipe away any excess.

2. Lightly apply multipurpose grease to the outside of the swivelassembly before installing in the cutter tube.

Clean and lubricate knife articulating arm (f)

Wipe away old grease. Lightly apply multipurpose grease.

Clean and lubricate cutter tube (g)

1. Wipe out old grease.

2. Lightly apply multipurpose grease to the inside of the cutter tube.

Reassemble

1. Follow the assembly procedures on page 104.

2. Then check bristle penetration on page 112.

(a)

(b)

(c)

(e)

(f)

(g)

(d)



Head — Sharpener AssemblyTurn off power at the C200 controller and open the head cover.

Perform sharpener assembly maintenance and knife bladealignment, as necessary

Follow the procedure on page 107.

Clean and film coat the knife presser foot slide rod (a) and rodguide (b)

Wipe clean. Lightly apply 10 weight synthetic oil.

Clean and film coat the air cylinder rod for the knife presser foot

1. Reduce air pressure to the head. Lower the air cylinder (c).


Perform knife guide alignment, as required

Follow the procedure on page 110.

DrillTurn off power at the C200 controller.

Clean and film coat the up/down air cylinders (a) for each drillunit

1. Reduce air pressure to the head. Lower the drill unit to access thetwo air cylinder rods.


3. Repeat for the auxiliary drill, if available.

Clean and film coat the air cylinder rods (b) for the drill presserfoot

1. Reduce air pressure to the head. Lower the presser foot.


(b)

(a)

(c)

(a) (b)



Beam

Inspect, clean, and film coat the Y–axis roundway (a)

1. Turn off power at the C200 controller.

2. Check for scratches, nicks, and gouges which can damagebearings. If found, contact Field Service.

3. Check for debris. Wipe clean. Lightly apply 10 weight syntheticoil.

Clean and film coat the Y–axis squareway (b)



Table

Inspect, clean, and film coat the X–axis roundways (c)


2. Check for abrasions or scoring. If found, contact Field Service.

3. Check for debris. Wipe clean. Lightly apply 10 weight syntheticoil.

Inspect the X–axis racks (d)


2. Check for damaged teeth, scoring or abrasion. If found, contactField Service.

3. Check for excess debris and wipe away.

Table — Vacuum

Clean the vacuum intake filter

1. Turn off power at the C200 controller. For Static and ZVCsystems, turn off power at the external vacuum assembly.

2. Remove the nut and bolt and then the retaining ring. Remove thecover (indicated).

3. Remove the wing nut and then remove the screens and filter.Vacuum the filter, screens, and inside of the drum. Soak the filter,if necessary.

4. Reinstall the filter and cover.

(b)

(a)

(d)

(c)



Table — Vacuum (contd.)

Check for fluid in air/reducer filters

1. Turn off power at the C200 controller. For Static and ZVCsystems, turn off power at the external vacuum assembly.

2. Take note of the air pressure setting. For each of two filters, turnthe top cap (a) to reduce air pressure before proceeding.

3. Loosen the drain plug (b) at the bottom of the filter.

4. Allow any fluid to drain out.

5. Retighten the drain plug and reset the air pressure.

(a)

(b)




Depending on the number of shifts required by your production schedule, thefollowing maintenance procedures need to be performed at least once andpossibly three times per week. These procedures include:

• Cleaning, lubricating, and checking X, Y, and C–axis gears.

• Checking drive belt tension.

• Checking head stops.

WARNING! To prevent injury, turn off the main circuit breaker for the C200controller before performing maintenance procedures, unlessinstructed otherwise.



Head — C–axis Drive

Check C–axis drive belt (a)


2. Check for wear or damage. To prevent slippage, the belt must bewiped free of any grease.

3. Check belt tension. There should be approx. 6 or 7 mm (1/4 in.)deflection at the center of the belt. Replace the belt, if needed.See page 113.

Clean, lubricate, and check C–axis servo gearing (b)


2. Wipe away old grease. Check for wear and damaged teeth.

3. Lightly apply multipurpose grease.

(a)

(b)



Head — Knife Drive

Check tension of knife drive belts


2. Check for belt wear or damage. To prevent slippage, the belt mustbe wiped free of any grease. Replace the belt, if needed.

3. Check belt tension. Adjust, if needed. See page 114.

Check mechanical alignment of the knife

1. Use the Heel to Heel Cut Test diagnostic along with the knifealignment box. See chapter 7.

2. Adjust mechanical knife offset, if needed. See page 111.

Check head upper stop


2. With the head assembly up (as shown), set the flywheel (a) at thetop of its stroke (TDC).

3. Adjust the upper stop (b) until the corner edge of the knife blade isin the middle of the lower grinding wheel (shown).

Check head lower stop

1. Remove air pressure from the head. With the head assembly down(not shown), set the flywheel (a) at TDC.

2. Adjust the lower stop (c) until the tip of the knife blade penetratesthe bristle to proper depth. See below.

Flywheel Stroke Depth

13/16 in. 1/8 in. (3.2 mm)

1 in. 1/16 in. (1.6 mm)

Chopping 3/8 in. (9.3 mm)set @ BDC

(b)

(c)

(a)

CornerEdge

TableSurface

GrindingWheel



Drill

Check the drill belt(s)

1. Turn off power at the C200 controller and remove the drill motorcover (indicated).

2. Check for belt wear or damage. To prevent slippage, the belt mustbe wiped free of any grease. Replace the belt, if needed.


Beam X and Y–axes Gearing

Clean, lubricate, and check first X–axis pinion gearing (a)

1. Turn off power at the C200 controller. Remove the beam controlpanel cover.

2. Wipe clean and check gears for nicks. Check for a slight amountof backlash between gearing.

Note: Check in several places in case there are any high spots inthe gears or racks.


Clean, lubricate, and check first X–axis servo gearing (b)

Same as above.

Clean, lubricate, and check Y–axis countershaft gearing (c)

Same as above.

Clean, lubricate, and check Y–axis servo gearing (d)

Same as above.

Clean, lubricate, and check second X–axis pinion gearing (e inboth views)

1. Turn off power at the C200 controller. Remove the end cap cover.

2. Wipe clean and check gears for nicks. Check for a slight amountof backlash between gearing.

Note: Check in several places in case there are any high spots inthe gears or racks.


Clean, lubricate, and check second X–axis servo gearing (f)

Same as above.

(a)

(b)

(e)

(g)

(f)

(e)

(c)

(d)

(g)



Beam — X and Y–axes Gearing (contd.)

Check the torque tube drive belts (g on previous page)

1. Turn off power at the C200 controller. Remove the beam controlpanel and end cap covers.

2. At both sides of the beam, check for wear or damage. To preventslippage, the belts must be wiped free of any grease. Replace thebelt(s), if needed.


Clean, lubricate, and check wheel housing cam rollers

1. Turn off power at the C200 controller. Remove the beam controlpanel cover as needed to access zerk fittings.

2. Find four cam rollers (a) on the beam control side of the cutter(two shown; two on the squareway side of the beam).

3. Check for any binding against the roundway when moving thebeam along the full length of the table. Adjust cam rollers, ifneeded. See page 125.

4. Fill zerk fittings on each cam roller with multipurpose grease.

Clean and lubricate first X–axis wheel assembly

1. Turn off power at the C200 controller. Remove the beam controlpanel cover cover as needed to access zerk fittings.

2. Find zerk fittings on two wheel assemblies (b), one shown. Fillwith multipurpose grease.

Clean and lubricate second X–axis wheel assembly

1. Turn off power at the C200 controller. Remove the end cap coveras needed to access zerk fittings.

2. Find zerk fittings for two wheel assemblies (c), one shown fromthe back. Fill with multipurpose grease.

(a)

(b)(a)

(c)



Beam — X and Y–axes Gearing (contd.)

Perform X–axis spring scale test

See procedure on page 127.

Perform Y–axis spring scale test

See procedure on page 127.

Beam — Bite Encoder

Clean and inspect bite encoder wheel (TCW and ZVC)


2. Check that the grit on the encoder wheel is not worn away.

3. Remove any plastic that might be wrapped around the wheel.

4. Tighten the set screw on the collar, as needed. Check that thewheel remains positioned directly over the bite indicator strip(s)along the edge of the cutting table.

Table — Clamp Bar (TCW)

Clean and film coat the clamp bar air cylinders

1. With power on, lower the clamp (shown in up position).

2. Wipe away debris from two air cylinder rods. Lightly apply 10weight synthetic oil.

Table — Resealer Option (TCW)

Clean and film coat the resealer air cylinder rods

1. With power on, run the Input Output Test (DG 23) diagnostic.See chapter 7.

2. Raise the resealer bar (a).

3. Wipe away debris from the air cylinder rods, one located in eachend post (b). Lightly apply 10 weight synthetic oil.

Check resealer bar up/down air flow adjustment

1. Raise and lower the resealer bar, checking for even motion.

2. If up or down motion is uneven, adjust air flow by turning theadjustment screw (c) on the hose connector for each air cylinder.

Bite Encoder for TCW

Bite Encoder for ZVC

(a)

(b)

(c)




Depending on the number of shifts required by your production schedule, thefollowing maintenance procedures need to be performed three to six timesyearly. These procedures include:

• Running diagnostics to check knife or drill speed and that the beam issquare.

• Checking beam bearings.

• Checking table and vacuum components.




Head

Check knife speed adjustment(should be OK for one year)

1. With the power on, use the Parameter Manager to set a low knifespeed.

2. Run the Input Output Test (DG23) diagnostic to enable the knifedrive. See chapter 7. Use a tachometer or strobe light to verify thelow speed setting.

3. If necessary, adjust the Zero and Max potentiometers on the knifedrive board.

4. See adjustment procedure and warnings onpage 115.

5. Repeat steps 1 through 4, setting and verifying a high knife speedsetting.



Drill

Check drill speed adjustment for each drill unit(should be OK for one year)

1. With the power on, use the Parameter Manager to set a low drillspeed.

2. Run the Input Output Test (DG23) diagnostic to enable the drilldrive. See chapter 7. Use a tachometer or strobe light to verify thelow speed setting.

3. If necessary, adjust the Zero and Max potentiometers on the drilldrive board.

4. See adjustment procedure and warnings onpage 119.

5. Repeat steps 1 through 4, setting and verifying a high drill speedsetting.

6. Repeat for the auxiliary drill, if available.

Beam — Y–axis

Check Y–axis roundway bearings


2. Attempt to physically move the cutter head from side to side. Ifyou notice movement, adjust the roundway bearings (a).See page 126.

3. Note: There should be no binding on the Y–axis.

Check Y–axis squareway bearings


2. Attempt to move the cutter head up and down. If you noticemovement, adjust the squareway bearings (b). See page 126.

3. Note: There should be no binding on the Y–axis.

(a)

(b)



Beam — Y–axis (contd.)

Check Y–axis belt


2. Push the cutter head toward the operator workstation.

3. Check the belt for signs of wear or fraying. Replace if damaged.

4. Check belt tension by inserting several fingers under the belt at alocation approx. 60 cm (2 ft.) from the end cap cover. You shouldbe able to raise the belt 2.5 to 3.8 cm (1 to 1 1/2 in.) only.

5. Adjust the tension, if needed. See page 128.

Check if beam is square

1. Run the Beam Square Test diagnostic. See chapter 7.

2. Square the beam, if needed. See page 129.

Table — Vacuum

Check vacuum generator belts (Spencer turbine)

1. Turn off power at the C200 controller. For Static and ZVCsystems, turn off power at the external vacuum assembly and atthe table control or lay puller panel.

2. For TCW systems, remove front ramp. For Static and ZVCsystems, remove the jack shaft cover.

3. Check the belt(s) for wear or fraying. Replace all belts, even ifonly one is damaged.

4. Check belt tension by depressing the center of the belt(s) betweenthe vacuum motor and vacuum turbine. Compare the deflectionamount with manufacturing specs.

5. To adjust or replace the belt(s), see page 136.




Check vacuum generator belts (Hoffman blower with pillow blockassembly)

1. Turn off power at the C200 controller. Turn off power at theexternal vacuum assembly and at the table control or lay pullerpanel.

2. Check the belt(s) for wear or fraying. Replace if damaged.

3. Check belt tension by depressing the center of the belt between thevacuum motor and the pillow blocks. Compare the deflectionamount with manufacturing specs.

4. To adjust or replace the belt(s), see page 136.

Clean vacuum stack filter

1. Turn off power at the C200 controller. For Static and ZVCsystems, turn off power at the externalvacuum assembly and at the table controlor lay puller panel.

2. Use a step ladder to reach the stack.

3. Remove the wing nut and then the filterand screens from the top of the vacuumstack filter.

4. Clean the filter by soaking.

5. Reinstall or replace, if needed.



Table — Material Handling (TCW and ZVC)

Check conveyor drive alignment

1. Place a typical production spread on the spreading table.

2. At the Platform control panel (TCW shown), set the ConveyorMode to Manual.

3. Jog the conveyor.

4. If the conveyor movement is not satisfactory or the motor“growls” for too long before the conveyor begins moving, adjustpotentiometers on the drive board.

5. See warnings and procedure on page 139. Seealso the documentation for the conveyor drive.

Table — Material Handling (Static)

Check lay puller drive alignment

1. Position a typical production spread in the lay puller.

2. Jog the lay puller.

3. If the lay puller movement is not satisfactory or the motor“growls” for too long before the lay puller begins moving, adjustpotentiometers on the drive board.

4. See warnings and procedure on page 140.




Depending on the number of shifts required by your production schedule, thefollowing maintenance procedures need to be performed two to three timesyearly. These procedures include:

• Checking knife and drill motor bushings.

• Checking fluid levels of gear boxes for conveyor and surface cleaner.

• Cleaning and lubricating platform components.

• Lubricating vacuum motor and turbine/blower.

• Checking overhead cable trolley.




Head

Check knife drive motor brushes

1. Turn power off at the C200 controller.

2. Remove two bushing caps (one shown) to gain access to the motorbrushes.

3. Check for excessive wear. Replace the brushes and caps, asneeded. See page 115.

Drill

Check drill motor brushes

1. Turn power off at the C200 controller. Remove the drill drivemotor cover (indicated).

2. Remove two caps to gain access to the motor brushes.

3. Check for excessive wear. Replace the brushes and caps, asneeded. See page 119.



Table — Vacuum

Lubricate Baldor vacuum motor

1. Turn power off at the C200 controller. For Static and ZVCsystems, also turn off power at the external vacuum assembly andat the table control or lay puller panel.

2. Remove the front ramp for TCW only. Find two zerk fittings onthe vacuum motor (indicated).

3. Fill with lithium–based grease.

Lubricate Spencer vacuum turbine

(Required more often for extreme ambient temperatures, bearingtemperatures of 120 to 170 deg F, and in very dirty operatingconditions; required less often for intermittent operation.)

1. With the front ramp removed (TCW only), find two fill cups onthe vacuum turbine (indicated).

2. Insert a clean, metal probe into each cup several times to a depthof 35 mm (1 1/2 in.).

3. Remove the probe and fill with Chevron SRI #2 grease.

4. Repeat insertion of probe and filling with grease three or fourtimes.

Lubricate Hoffman blower (a)(should be OK for 1800 to 2000 hours)

1. Turn power off at the C200 controller. Also, turn off power at theexternal vacuum assembly and at the table control or lay pullerpanel.

2. At the end of the blower, open the top and bottom plugs (notshown).

3. Insert a metal rod through the top plug opening and push oldgrease out of the bottom plug opening.

4. Fill from the top with Chevron SRI #2 grease until clean greasecomes out of the bottom plug. Replace the plugs.

Lubricate pillow blocks (not shown)

1. Depending on the setup of the external system, find zerk fittingson two pillow blocks.

2. Fill with lithium–based grease.

Motor

Turbine

External VacuumSystem with Blower

(a)

(b)




Check Hoffman coupling alignment

1. Turn power off at the C200 controller. Also, turn off power at theexternal vacuum assembly and at the table control or lay pullerpanel.

2. Remove the coupling guard (b on previous page).

3. Use hot system method to check coupling alignment.See page 137.

4. Use cold system method to adjust alignment. See page 137.

Table — Material Handling (TCW and ZVC)

Check fluid level of conveyor gear box(change every third time)


2. For TCW systems, remove the front ramp and several slats to gainaccess to the gear box. For ZVC systems, remove the take–oncover.

3. Remove the fill screw from the gear box. Check the oil level.

4. As required, add SAE 600 weight oil to the center line of the shaft.

Table — Material Handling (Static)

Check fluid level of lay puller gear box(change every third time)


2. Remove the oil level plug at the side of the gear box. Check the oillevel.

3. As needed, add SAE 600 weight oil through the vent fitting up tothe oil level fitting.



Table — Surface Cleaner (TCW)

Check fluid level of surface cleaner gear box(change every third time)


2. Remove the cover (a) for the gear box.

3. Remove the fill screw on top of the gear box and check the fluidlevel.

4. As required, add SAE 600 weight oil to the level indicated on theside of the gear box.

Lubricate surface cleaner pillow block bearings


2. Open each access door (b in both views) at the take–off end of thecutter.

3. Using a flashlight, locate each of two pillow block bearings, oneon opposite sides of the cutter (c in both views indicates generallocation).

4. Each bearing has a zerk fitting. Fill with multipurpose grease.

Table — Platform Drive (TCW)

Clean and lubricate platform drive chain

1. Turn power off at the C200 controller. Also, turn off power to thetable control panel.

2. Remove round black plates, two located on the remote side(d – one shown) and one located on the operator side of the cutterbehind the GERBERcutter name panel.

3. Lighly apply multipurpose grease to the chain.

4. Manually reposition the chain, as needed to complete the job.

Lubricate platform drive sprocket bearings


2. Locate four zerk fittings on the sides of the cutter as shown atright.

3. Fill with multipurpose grease.

(b)

(c)

(a)

(b)

(d)

(c)

Location of drivesprocket zerk fittings

on cutter



Table — Platform Drive (contd.)

Lubricate platform drive cam roller bearings


2. Remove the front ramp and several slats to gain access to two camroller bearings, each with one zerk fitting.

3. Fill with multipurpose grease.

Check fluid level of platform drive gear box(change every third time)


2. On each side of the cutter, remove covers over the platform drivewheel assemblies (a).

3. Remove the fill screw from the gear box. Check the level.

4. As required, add SAE 600 weight oil to the center of the shaft.

Lubricate platform drive shaft bearings


2. On the remote side of the cutter, remove the cover from theplatform drive wheel assembly. On the operator side of the cutter,find the access holes.

3. Fill zerk fittings on each drive shaft with multipurpose grease(four fittings total).

Lubricate platform wheel cam roller bearings


2. Find the access holes (b) in the covers for the platform drivewheel assemblies, one assembly on each side of the cutter at thetake–off end.

3. Fill zerk fittings on each wheel cam roller bearing withmultipurpose grease (four fittings total).

(a)

(b)



Table — Overhead Cable Trolley (TCW)

Check roller and clamps for overhead cable trolley

1. Turn power off at the C200 controller. Also, turn offpower to the table control panel.

2. Wipe roller bearings clean.

3. Lubricate sparingly with multipurpose grease.

Cover Maintenance


Cutter HeadThe cutter head contains the knife andperforms the actual cutting of material.It moves across the cutting table on the beam.

Cutter head assemblies covered in this sectionare listed in the table below.

Assembly See Page

Cover 103

Knife Drive Train 104

Knife 106

Sharpener Assembly 107

Knife Guides and Offset 109

Elevator 112

C–axis Drive 113

Knife Drive 113

Cover

The cover encloses the cutter head. It is atwo–piece unit that protects the cutter headcomponents from damage and the operatorfrom injury.

Open/Remove


WARNING! To prevent injur y, turn offthe main circuit breaker for theC200 controller beforeperforming maintenanceprocedures, unless instructedother wise.

2. Lift to open (or raise) the front coversection.

3. If it is necessary to remove the front andback sections of the cover:

a) Remove all screws that attach theback cover section to the frame.

b) Slide the two cover pieces up and offthe cutter head.

WARNING! Do not routinel y operatethe GERBERcutter without thecutter head covers; this couldcause injur y.

Install/Close

1. If the front and rear sections of the coverwere removed:

a) Slide the two cover pieces over thecutter head so that they rest in thegroove of the cutter head.

b) Replace and tighten all screws thatattach the back cover section to theframe.

SharpenerAssembly

C–axisMotor

KnifeDriveTrain

ElevatorAssembly

KnifeDrive

CutterTube

Knife Drive Train Maintenance


2. Lower and close the front head cover.

3. If you are through with maintenance,Turn on power at the C200 controller.

Knife Drive Train

The knife drive train moves the knife andworks with the C–axis gear to let the knife cutcorners, notches, curves, and other complexshapes. The drive train is comprised of aflywheel, connecting rod, pivot block, swivellink, swivel assembly, and knife.

Maintenance procedures related to thispart of the cutter are covered in the 8 hourmaintenance schedule.

WARNING! The knife is very sharp.To prevent personal injury,exercise care in handling theknife during any maintenanceprocedure.

Remove


2. Open the cutter head cover.

3. Remove screw 2 which fastens the swivellink to the pivot block and articulatingarm.

4. Lower the swivel link into the cutter tube(see previous page).

5. Disconnect the connecting rod from theflywheel by removing screw 1.

6. Pull the swivel link, swivel assembly, andknife out of the cutter tube.

Inspect

1. Wipe away old grease from the:

− Articulating arm.

− Inside of the cutting tube.

− Swivel assembly.

2. Inspect the swivel assembly for gouges,cracks, and other damage. Rotate the stemof the swivel assembly several times tocheck for binding. If there are any defectsor the stem binds, replace the assembly.

Flywheel

Screw 1

Screw 2

Pivot Block and Articulating Arm

Connecting Rod

Swivel Link

Swivel Assembly

Knife

Knife Drive Train Maintenance


Required Supplies GGT Part No.

swivel lube kit 031154000

EP2 lubricant 596500006

Lubricate

1. Using the grease gun with the 0.050 in.needle installed, inject grease into thelubrication hole of the swivel until itstarts to seep out around the stem. Wipeoff excess grease.

CAUTION: Excess lubricants can damagefabric. Apply sparingly.

2. Using multipurpose grease, lightly coatthe:

− Outside of the swivel assembly.

− Inside of the cutter tube.

− Pivot block of the articulating armassembly.

Install

1. Insert the swivel link, swivel assembly,and knife into the cutter tube.

2. Fasten the connecting rod to the flywheelwith screw 1.

3. Reposition the articulating arm. Fastenthe swivel link to the pivot block andbushing assembly with screw 2.

4. Lower and close the front head cover.

5. Turn on power at the C200 controller andrun the C200 program.

6. Check the knife penetration into thebristle. See page 112.

CAUTION: Always check bristle penetrationwhen you install a new knife.Failure to check the depth ofbristle penetration can damagethe work surface.

7. Check knife operation:

a) At the beam control panel, set theknife switch to ON.

b) Check that the knife moves smoothlywith no unusual noise. If you noticeany problems, call your servicerepresentative.

c) At the beam control panel, set theknife switch to OFF.

8. At the operator workstation, use the NewKnife command in the Cutter menu toreset the knife wear logic.

9. Execute several sharpening cycles bypressing the SHARP button on the beamcontrol panel.


Lubrication Hole

Knife Maintenance


Knife

The knife is the part of the cutter head thatactually cuts the material. It is attached to thelower end of the knife drive train. Good cutquality depends on a properly sharpened,undamaged knife.


Inspect


2. Check the knife for excessive wear andimproper sharpening.

Good Unacceptable

3. If necessary, install a new knife.

Remove



3. Remove the knife drive train (see page104).

4. Remove screw 1 that fastens the knife tothe swivel assembly.

5. Slide the old knife out of the swivelassembly.

Install

Note: Knife sizes and types are available fordifferent applications. See the table onpage 170. If you are unsure about thesize or type of knife in your system,contact Field Service.

1. Inspect the new knife for flaws beforeinstalling it.

2. Slide the knife into the swivel assembly.

3. Install screw 1, but do not tighten it.Notice that the hole is offset to preventinstalling the knife backwards.

4. While holding the knife and swivel link,place against a firm surface and pushdown on the knife and swivel. Tightenscrew 1.

Or, hold as shown below. Whilemaintaining the pressure, have anassistant tighten screw 1. This seats theback of the knife in the back of the swivelassembly.

5. Install the knife drive train.

6. Check bristle penetration. See page 112.

CAUTION: Always check bristle penetrationwhen you install a new knife.Failure to check the depth ofbristle penetration can damagethe work surface.

7. If you are through with maintenance:

a) Lower and close the front head cover.

Sharpener Assembly Maintenance


b) Turn on power at the C200 controller.

Sharpener Assembly

Sharpener maintenance is critical to cutterperformance, because it keeps the knife sharp.A dull knife causes material fusing and poorperformance. Worn or dirty grinding wheelscan cause uneven sharpening.

Procedures in this section are included inthe 8 hour maintenance schedule.

Note: Grinding wheel mesh variesaccording to application and size andtype of knife. Contact your FieldService representative for moreinformation.

CAUTION: To prevent damage to the cutterand/or fabric, only qualifiedoperators or maintenancepersonnel who have receivedGERBERcutter training shouldperform the followingprocedures.

Inspect

1. Use the checklist below as you removeand disassemble the sharpener assembly.

99 Part Check For

sharpenerassembly

dirt and lint build–up

KI connectorsand cable

damaged cable or looseconnectors

grinding wheelpulley drivebelts (O-rings)

cracks, stretching, or oildeposits

yoke arms excessive play on thepinion wheel shaft

grinding wheels deterioration and particlebuild–up

latch spring andclamp

bends, wear, or otherdamage

presser footbowl shafts

scratches, nicks, or gouges

upper knifeguide

any damage

lower knifeguide and rollers

scratches, nicks, or gouges

2. If you see any of the conditions describedabove, replace the appropriate part. If youare unsure why the damage resulted, callyour Field Service representative beforereplacing.

LatchSpringClamp

PresserFoot BowlShaft Locations

YokeArms

Cutter TubeLocation

UpperPulley

Grinding WheelAssembly

Spring

Sharpener Assembly Maintenance


Remove



3. Remove the knife drive train (see page104).

4. Pull the swivel link, swivel assembly, andknife out of the cutter tube.

5. Unplug the two connectors for the KnifeIntelligence (KI) transducer.

6. Loosen the mounting screw (shownbelow) that holds the sharpener assemblyon the cutter tube.

7. Lower the sharpener assembly andremove it from the cutter head.

Disassemble

1. Remove the foot spring (shown onprevious page).

2. Remove the presser foot bowl assembly.

3. Remove the latch spring clamp.

4. Stretch the grinding wheel pulley beltsover each pulley. Then slide the pulleysout of the yoke arms.

Clean and Lubricate


Loctite Safety Solvent 308010101

grinding wheel (60 mesh) 036779000



belt, pulley (O-ring) 496500215

CAUTION: Do not spray solvent near KIconnector.

1. Using a clean cloth and either denaturedalcohol or Loctite solvent, clean:

− Inside the cutter tube.

− Grinding wheels (replace if worn).

− Grinding pulley belts.

− Upper knife guide.

− Presser foot bowl shafts.

− Air cylinder rod.

2. Using a clean rag dampened with SAE 10oil, lubricate the presser foot bowl shaftsand air cylinder rod.

CAUTION: Excess lubricants can damagefabric. Apply sparingly.

MountingScrew

KIConnector

Wire

PresserFootBowl

Air CylinderRod

Knife Guides and Offset Maintenance


Assemble

1. Install the grinding wheels and grindingpulley belts on the yoke arms.

Note: You should keep a spare set ofgrinding wheels. When you need tochange the grinding wheels, replacethem with the spare set and resumecutting.

2. Install the latch spring clamp.

3. Install the presser foot bowl assembly.

4. Install the foot spring.

Install

1. Place the sharpener assembly onto thecutter tube. Tighten screw 1 that holds thesharpener assembly on this tube.

2. Plug in the KI connectors.

3. Coat both sides of the knife with ink froma black marker with a broad tip.


4. Install the knife drive train. See page 106.

5. Turn on power at the C200 controller andrun the C200MT program.

6. On the beam control panel, set the knifeswitch to ON.

7. Execute 10 sharpening cycles by pressingthe SHARP button on the beam controlpanel.


9. Remove the knife drive train.

10. Inspect the grinding pattern in the ink onthe knife. It should be equal on both sidesand extend from the cutting edge back. Italso should extend from the heel of theblade to about 100 mm (4 in.) above theheel.

− If the pattern is not acceptable, callyour service representative.

− If the pattern is acceptable, install theknife drive train.




Knife Guides and Offset

Alignment of the upper and lower knifeguides must be done whenever you replacecomponents in the sharpener assembly thataffect knife guide alignment. These includethe upper or lower knife guides and rollers inthe presser foot.

LowerGuideRollers

PresserFoot



Knife Guides

Align


2. Remove the knife drive train and thesharpener assembly. See pages 104 and108.


3. Check the knife blade alignment asfollows:

a) Hold the sharpener assemblyhorizontally in one hand and pull thepresser foot bowl away from thesharpener assembly approximately100 mm (4 in.).

b) Guide a knife through the upperguide, making sure the back of theknife fully contacts all three runnersin the upper guide (shown at top left).Check that back of the knife blade justcontacts the rear roller of the lowerguide.

c) If the knife blade does not aligncorrectly, shims placed in the upperguide may correct the alignment.The shim material used is a laminated1/32 in. round washer made up ofnumerous layers of brass shim stock0.002 in. thick. To adjust shimthickness, you can separate theselayers with a pocket knife.

Note: Appropriately placed shimsshould remain in place untileither the upper or lowerguide is replaced.

4. Install the sharpener assembly and knifedrive train.

5. Make sure that the knife blade movesfreely through the cutter tube andsharpener assembly.




Correct alignment is when theback of the blade contacts roller.

Back of blade must contact all 3 runners flatly.

Sharpener housing

Make sure all parts are in spec.Shimming may not be possible in this case.

Shim these points between the upperguide and sharpener housing.

Upper knife guide

Rear roller oflower guide



Knife Offset

The knife should produce a cut pattern thatcan be aligned heel–to–heel as shown belowwith the correct distance measurement.

Inspect


knife alignment box 027014000

1. Place the knife alignment box on the tableand cover with plastic. Apply vacuum.

2. Run the Heel to Heel Test diagnostic. Seechapter 7.

3. If either the cut pattern is unacceptable orthe measurement is not within 12.7 to14.3 mm (0.5 to 0.56 in.), align asexplained below.

Good Unacceptable

Measurement

(b)(a)

Alignment

1. Turn off power at the C200 controller andopen the cutter head cover.

2. Loosen the four cutter block lockingscrews. Lower the presser foot bowl andloosen the four cutter tube locking bolts.

3. To correct the cut pattern, loosen the0 degree and 180 degree positioningscrews. Then adjust the 90 and 270degree positioning screws as follows:

− If the pattern looks like (a) shownabove, loosen the 90 degree screw andtighten the 270 degree screw.

− If the pattern looks like (b), loosen the270 degree screw and tighten the 90degree screw.

4. To correct the heel–to–heel measurement,loosen the 90 degree and 270 degreepositioning screws. Then adjust the 0 and180 degree positioning screws as follows:

− If the measurement was greater thanthe spec, loosen the 180 degree screwand tighten the 0 degree screw.

− If the measurement was less than thespec, loosen the 0 degree screw andtighten the 180 degree screw.

5. When adjusted, tighten the top four cutterblock locking screws and at least two ofthe bottom four cutter tube lockingscrews.

6. Turn on power at the C200 controller.

7. Run the Heel to Heel Test diagnosticagain to check knife alignment. Ifadditional alignment is required, repeatsteps 3 through 6 as needed.

8. When the knife has been adjustedcorrectly, tighten the 90 and 270 degreepositioning screws and all locking screws.

Note: Be careful not to over tighten thepositioning screws. These are meantto be used for adjustment only, andnot to secure the cutting block.

Cutter BlockLocking Screw

90 DegreeScrewLocation

180DegreeScrew

Location

Elevator Maintenance


Elevator

The elevator assembly is the frame thatsupports the knife drive gear, the knife drivetrain, and the cutter tube. The elevatorassembly rides up and down on two guiderods. The air cylinder rod connects theelevator assembly to the air cylinder piston.As the piston moves through the air cylinderit moves the rod. The rod in turn moves theelevator assembly.

The rods on which the elevator assemblymoves up and down must be kept free of dirtand grit so that the elevator assembly ridessmoothly.

Elevator Guide Rods

Check the guide rods for scratches, nicks, andgouges. These defects can damage thebearings in the elevator assembly. If you seeany of these conditions, call Field Serviceimmediately.

Air Cylinder Rod

Check the two elevator guide rods forscratches, nicks, and gouges. These defectscan damage the bearings in the elevatorassembly. If you see any of these conditions,call Field Service immediately.


Head Stops

To prevent knife damage to the bristle worksurface, elevator head stops limit the up anddown travel of the elevator. After checkingbristle penetration, the upper and lower headstops are adjusted. Check and make alladjustments with the flywheel at top deadcenter (TDC). Exception is for the choppingstroke, which is adjusted at BDC.

Bristle penetration refers to howfar the knife goes into the bristle.The correct distance is related to theflywheel stroke as shown in thetable below.

CAUTION: To prevent damage tothe bristle work surface, alwayscheck the adjustment for bristlepenetration after installing anew knife.

Flywheel Stroke Depth

13/16 in. 3.2 mm (1/8 in.)

1 in. 1.6 mm (1/16 in.)

Chopping 9.3 mmset @BDC (3/8 in.)

Maintenance procedures related to thispart of the cutter are covered in the 40hour maintenance schedule.

ElevatorAssembly

KnifeDrive

HeadUpper

Stop

HeadLower

Stop

C–axis Drive Maintenance


C–axis Drive

The C–axis drive belt links the knife driveservo gear to the knife drive train. The drivebelts and gears must be in good condition forthe best cutting performance.

Servo Gear

Check for wear and damaged teeth. Look forexcessive oil or grease on the gear. Call yourField Service representative if any of theseconditions exist.

Drive Belt

Check for wear or damage. To preventslippage, wipe the belt free of any greaseor oil. Belt deflection should be 6 or 7 mm(1/4 in.) at the center of the belt. Replace,if needed.


Adjust/Replace


belt, C–axis 180138037



3. Loosen three mounting screws on theC–axis motor. Sliding the knife motoraway from the knife drive train tightensthe drive belt. Sliding it towards the knifedrive train loosens the drive belt.

4. If needed, replace the belt.

5. Tighten the mounting screws and checkthe drive belt tension again. Repeat thetensioning procedure, as needed.




Knife Drive

Knife drive belts connect the knife drivemotor to the knife crankshaft through a seriesof pulleys. As the knife drive motor turns, thedrive belts transfer motion to the knifecrankshaft. The circular crankshaft motion istranslated to up and down knife motion by thearticulating arm assembly.

Tension and Pivot Arm Oil Cups

Fill the two tension arm oil cups and the pivotarm oil cup.


UpperTensioningBarMount

Drive MotorMounting

Plate

UpperDrive Belt

LowerDrive Belt

C–axisDrive

C–axisDrive Belt

Knife Drive Maintenance


Knife Drive Gearing and Belts

Check



3. Inspect all knife drive gears for excessivewear, damaged teeth, and presence ofexcessive oil. Call your Field Servicerepresentative if any of these conditionsexist.

4. Wipe clean with denatured alcohol on arag. Use a stiff brush as required forbuilt–up debris.

5. Inspect both knife drive belts for wear ordamage to the teeth. Check for grease oroil contamination. To prevent slippage,the belts must be free of any lubricant.

6. Check tension of the upper knife drivebelt with the elevator in the up position.Check tension of the lower knife drivebelt with the elevator in the downposition. The amount of deflection oneach belt should be about 6 or 7 mm(1/4 in.).


belt, knife drive to idler28 tooth

180138036

belt, idler to fly wheel22 tooth

180088001

belt, idler to fly wheel28 tooth

180138036

Adjust/Replace

CAUTION: To prevent premature wear, donot over tighten knife drive belts.If the drive belt makes excessivenoise when running, it may betensioned too tightly.

1. The upper drive belt is tensioned with theelevator in the up position. Loosen thetwo hex key bolts on the two piece uppertensioning bar. Sliding the drive gear, onthe knife assembly side of the cutter head,towards the knife will tighten the drivebelt. Sliding it towards the knife motorwill loosen the drive belt.

2. If needed, replace the upper belt.

3. Tighten the two adjusting bolts and checkthe drive belt tension again. Repeat thetensioning procedure, as needed.

4. The lower drive belt is tensioned with theelevator in the up position. Loosen fouradjustable mounting bolts on the knifemotor mounting bracket. Sliding the knifemotor away from the gearing tightens thedrive belt. Sliding it towards the gearingloosens the drive belt.

5. If needed, replace the lower belt.

6. Tighten the four adjusting bolts and checkdrive belt tension again. Repeat thetensioning procedure, as needed.




Knife Drive Maintenance


Knife Drive Motor

As part of normal maintenance, you shouldinspect the motor brushes for the knife drivemotor located on the flatway side of thebeam. Replace as needed.


brush, 2.3 hp Dumore motor 238040201

brush cap 632500010


Knife Speed

The knife drive motor is translated to theknife drive train through two drive belts. Theactual knife speed should be checked againstC200MT parameter settings for knife speed.Verify with a tachometer or strobe light andadjust as needed.


Check

1. Run the C200MT program and open theParameter Manager.

2. In the Knife and Drill Speed category, seta low knife speed of 1500 ± 100 rpm.

3. Run the Input Output Test (DG 23)diagnostic. See chapter 7. Enable theknife drive motor.

4. Check the knife speed using a tachometeror strobe light.

5. Repeat steps 2 through 4, setting a highknife speed of 5000 ± 100 rpm.

6. To adjust knife speeds, if needed,qualified personnel can refer to thejumper and potentiometersettings/instructions on GGT technicaldrawing, part number 078774000.

WARNING! High voltagesexist inside the vacuum andplatform control enclosure, theC200 controller, and the cuttingtable. There are no operator–serviceable parts inside theseelectrical areas. Only qualifiedpersonnel should performmaintenance on theseassemblies. Failure to followthese instructions could causeinjury or death.

Drill Bit Maintenance


Electric DrillIf your S91 GERBERcutter is equipped withthe electric drill option, you will need toperform the maintenance proceduresexplained in this section. The drill assemblymounts to the subplate at the back of thecutting head. If there are two electric drillunits on a cutter, one mounts in front of theother and is referred to as the auxiliary drill.

Although one drive motor runs both drills,parameters in the C200MT software allow forindependent control of each drill. And, youcan run with drill bits of different sizes.

Assemblies covered in this section are listedin the table below.

Assembly See Page

Drill Bit 116

Drill Assembly 118

Drill Bit

The drill bit is the part of the drill that cutsholes in the material. Drill bits are availablein a variety of sizes and types. See the tableon page 171.

CAUTION: When replacing the drill bit,remember to match the drill bitsize to the appropriate size colletsand ejector rod (for hollow bitdrills).

Remove


2. For hollow bit drills, remove the ejectorrod:

a) Remove the drill motor cover byremoving the two wing nuts.

b) Using two wrenches, hold the chucknut in place while loosening the uppercollet.

c) Slide the ejector rod up and out.

3. Remove the drill bit:

a) Press and hold the detent (shown onnext page) while manually turning thedrill pulley until the pulley locks inplace.

Note: The pulley can be reached frombehind the drill motor cover.

b) Hold down the safety spring. Thendepress the detent while loosening thelower collet.

c) Remove the drill bit through thepresser foot.

DrillMotorCover

PresserFoot

DrillBit

AirCylinderRod

Drill Bit Maintenance


4. Loosen the set screw that retains the drillbushing. Remove the bushing.

5. If installing a different–sized drill bit,remove the upper and lower collets.

Install

1. If you are installing a different–sized drillbit, install the appropriate collets for thedrill bit size and leave them loose. See thetable on page 171.

2. Insert the new drill bit. Install the drillbushing and tighten the set screw.

3. The tip of the drill should be inside of thelower bushing when the drill is in theraised position. If not, loosen the twocollar clamps, one on each presser foot aircylinder, and raise or lower the presserfoot assembly until the drill tip is insideof the bushing. Tighten the collar clamps.

See step 4b.

4. For hollow drill bits, install the ejectorrod:

a) Use the correct–sized ejector and slidethe ejector rod down through theupper collet.

b) Align the ejector rod so that it is 1.5to 3 mm (1/16 to 1/8 in.) lower thanthe bottom of the drill when the drillunit is up.

c) Tighten the upper collet finger tight.Using a wrench, tighten 1/4 turnmore.

d) Tighten the chuck nut 1/4 turn more.

5. Check drill penetration into the bristle:

a) Remove air pressure to the drill.Manually, lower the drill to its lowerlimit. Or, turn power on and use theInput Output Test (DG 23) to lowerthe drill.

b) Mark the drill bit at the point it entersthe bristle. Measure the distance fromthe drill tip to this mark. Themeasurement should be 6 or 7 mm(1/4 inch).

See step 5b.

6. If necessary, adjust by loosening thelower collet and repositioning the drill bit.

7. Install the drill motor cover, if removed.

8. If you are through with maintenance,Turn on power at the C200 controller.

Detent

Set Screw

DrillBushing

Drill Assembly Maintenance


Drill Assembly

Air Cylinder

There are three air cylinder rods for eachelectric drill unit. Two air cylinder rods raiseand lower the drill presser foot. One aircylinder rod raises and lowers the drill unit.These rods must be kept free of dirt and gritso that the drill assembly rides smoothly.


Drive Belt

Check the drive motor belt for wear ordamage. To prevent slippage, wipe free ofany grease or oil. Replace the belt, if needed.


Check


2. Remove the drill motor cover.

3. Inspect the belt for wear or damage to theteeth. Check for grease or oilcontamination. To prevent slippage, thebelt must be free of any lubricant.Replace, the belt as needed.

4. Check belt tension. The amount of beltdeflection midway between the drillmotor and pulley should be about 6 or 7mm (1/4 in.).


belt, standard drill, 1.6 hpbelt, GM

180138003

belt, heavy duty drill, 2.3 hp 180078009

belt, 1/4 in. dual drill 0.5 hp,inner drill

180138003

belt, 1/4 in. dual drill 0.5 hp,outer drill

180138001

belt, 1/4 in. dual drill 2.3 hp,inner drill

180078009

belt, 1/2 in. dual drill 2.3 hp,outer drill

180500020

Adjust/Replace

CAUTION: To prevent premature wear, donot over tighten the drill drivebelt(s). If a drive belt makesexcessive noise when running,it may be tensioned too tightly.


2. Remove the drill motor cover.

3. Loosen four adjustable mounting bolts onthe drill motor mounting bracket.

4. Replace the belt(s), as needed.

5. Adjust by sliding the drill motor awayfrom the drill to tighten the drive belt.Sliding it toward the drill loosens thedrive belt.



6. Tighten the four adjusting bolts and checkthe drive belt tension again. Repeat thetensioning procedure, as needed.


a) Install the drill motor cover.


Drive Motor

As part of normal maintenance, you shouldinspect the motor brushes for the drill drivemotor located under the drive motor cover.Replace the brush and cap, as needed.


brush, 2.3 hp Dumoremotor or 1.6 hp Boehmmotor

238040201

brush cap, Dumore motor 632500010


Drill Speed

The drill motor runs the heavy duty electricdrill(s). The actual drill speed of each drillunit should be checked against C200MTparameter settings for drill speed. Checkspeeds with a tachometer or strobe light andadjust as needed.


Check

1. Run the C200MT program and open theParameter Manager.

2. In the Knife and Drill Speed category, seta low drill speed of 1500 ± 100 rpm.

3. Run the Input Output Test (DG 23)diagnostic. See chapter 7. Enable the drilldrive.

4. Check the drill speed using a tachometeror strobe light.

5. Repeat steps 2 through 4, setting a highdrill speed of 5000 ± 100 rpm.

6. To adjust drill speeds, if necessary,qualified personnel can refer to thejumper and potentiometersettings/instructions on GGT technicaldrawing, part number 078774000.

WARNING! High voltagesexist inside the vacuum andplatform control enclosure, theC200 controller, and the cuttingtable. There are no operator–serviceable parts inside theseelectrical areas. Only qualifiedpersonnel should performmaintenance on theseassemblies. Failure to followthese instructions could causeinjury or death.

Roundway and Squareway Maintenance


BeamThe beam transports the cutter head. Electricmotors drive the beam along roundways andracks on the cutting table and move the cutterhead along the beam. The cutter head travelson the beam along a roundway and a flatway.The combined motions of the beam and cutterhead allow the knife to cut complex patterns.

Beam assemblies covered in this section arelisted in the table below.

Assembly See Page

Roundway and Squareway 121

Covers 122

Basic X and Y–axes 122

Advanced X and Y–axes 126

Round way and Square way

The roundway supports and guides the cutterhead as it travels along the beam. It is a roundshaft that runs the length of the beam facingtoward the take–off end of the table. Thesquareway also supports and guides the cutterhead as it travels along the beam. This is a flatplate that runs the length of the beam on thetake–on end of the table. You must keep theroundway and squareway clean, lightlylubricated, and free of scratches so the cutterhead can move freely.

Inspect the roundway and squareway forscratches, nicks, and gouges. These defectscan damage the roundway or squarewaybearings in the cutter head subplate. Call yourservice representative immediately if you seethese conditions.

Inspect the beam roundway and squarewayfor dirt and built–up lint. Clean and lubricate.


WheelAssembly

Squareway

Second X–axisDrive

First X–axisDrive

Y–axisDrive

Roundway

CamRollers

Subplatefor CutterHead

RoundwayBearings

SquarewayBearings

Covers Maintenance


Covers

The beam control panel cover and end capcover protect the motors, gearing, and beltsthat move the beam along the length of thetable and move the cutting head across thebeam. These covers must be removed toperform many beam maintenance proceduresexplained in this section.

Remove


WARNING! To prevent injury, turn offthe main circuit breaker for theC200 controller beforeperforming maintenanceprocedures, unless instructedotherwise.

2. Remove the mounting screws that holdeither the beam control panel cover or theend cap cover in place.

3. Slide the cover up over the panel and offthe beam.

CAUTION: Do not routinely operate theGERBERcutter without the beamcontrol panel and end cap coversin place; this could cause damageto beam components.

Install

1. Slide the cover over the panel and cablesinto position on the beam.

2. Install and tighten the mounting screws.

3. If you are through with maintenance, turnpower on at the C200 controller.

Basic X–axis and Y–axis

X–axis gearing allows the beam to movealong the length of the cutting table. Y–axisgearing allows the head to move on the beamacross the width of the cutting table.The first X–axis gearing is located on thebeam under the beam control cover; secondX–axis gearing is located on the beam underthe end cap cover.

Beam

End CapCover

BeamControl Panel

Cover

Basic X–axis and Y–axis Maintenance


Servo Motor Gearing

The first and second X–axis (see below) andY–axis servo motor gears (see next page)should be lubricated regularly and must beadjusted so that there is a slight amount ofbacklash between the servo motor gear andthe driven gear.

Note: Check in several places in case thereare any high spots in the gears.

Maintenance procedures related to theseparts of the cutter are covered in the 40hour maintenance schedule.

Adjust


2. Remove the beam control panel and endcap covers.

3. To adjust, loosen the three mountingscrews for each servo motor and positionthe servo motor for a lesser amount ofbacklash.

4. Tighten the screws and check the amountf backlash again.


a) Install the beam control panel and endcap covers.

b) Turn power on at the C200 controller.

Servo Pinion Gearing and TorqueTube Belts

The first and second X–axis pinion gearsshould be lubricated regularly and must beadjusted so that there is a slight amount ofbacklash between the pinion and rack gears.

Note: Check in several places in case thereare any high spots in the gears orracks.

Maintenance procedures related to theseparts of the cutter are covered in the 40hour maintenance schedule.

Adjust/Replace


belt, X–axis 180138035



3. Adjust gearing on each side of the beam:

a) Loosen the idler pulley for the torquetube belt so that the belt is loose.

b) Disconnect the X–axis servo motorconnector.

c) Loosen the servo motor shoulderscrew, remove the other two servomotor mounting screws, and swingthe servo motor out of the way.

d) Turn the X–axis rack drive gear sothat the three holes in the gear line upwith the three mounting screws forthe rack drive assembly.

e) Loosen the three mounting screws forthe rack drive assembly andphysically adjust the rack drive for aslight amount of backlash. Check this.X–axis

Servo MotorRack andPinion Gears

First AxisTorque Tube Belt



4. Replace the torque tube belt, if needed.

5. Tighten the torque tube belt and tightenthe idler pulley screws.

6. Reinstall the servo motor with a slightamount of backlash. Check this.

7. Reconnect the X–axis servo motorconnector.

8. If you are through with maintenance,



Y–axis Countershaft Gear

The Y–axis countershaft gear should belubricated regularly and must be adjusted sothat there is a minimal amount of backlashbetween it and the Y–axis pulley gear.

Note: Check in several places in case thereare any high spots in the gears.


Adjust


2. Remove the beam control panel cover.

3. Adjust the gear:

a) Disconnect the Y–axis servo motorconnector.

b) Loosen the servo motor shoulderscrew, remove the other two servomotor mounting screws, and swingthe servo motor out of the way.

c) Loosen the three mounting screws onthe Y–axis countershaft assembly andphysically adjust for minimalbacklash.

d) Tighten the three mounting screws.

4. Check the amount of backlash again.

5. Reinstall the servo motor with a slightamount of backlash. Check this.

6. Reconnect the Y–axis servo motorconnector.


a) Install the beam control panel cover.


CountershaftGear

Y–axisServoGear



Wheel Housing Cam Rollers

The wheel housing cam rollers (four on thebeam control panel side of the beam) shouldbe lubricated regularly and must be adjustedso that there is no binding against theroundway as the beam travels the full lengthof the table.

Maintenance procedures related to thispart of the cutter are in the 40 hourmaintenance schedule.


hex wrench, 1/4 in. 020945000

Adjust


2. Remove the beam control panel cover.

3. Loosen the locking nut on the top of theinside cam roller.

4. Adjust the cam roller until it barelytouches the roundway at the tightest spoton the table.

5. Tighten the locking nut. Check again forany binding against the roundway as thebeam travels the full length of the table.


a) Install the beam control panel cover.


Wheel Assemblies

Check the four brass wheel assemblies (twoon each end of the beam) for wear or damage.Lubricate regularly.


Bite Encoder

The bite encoder tracks information about thecurrent bite for use by the C200MT program.It is attached to the take–on side of the beamnear the beam control panel (TCW shown).

Check the encoder wheel for worn areas onthe grit surface, wobbling, and correctpositioning over the bite indicator strip(s)along the edge of the table surface.


WheelAssembly

CamRollers

EncoderWheel

Bite IndicatorStrips

Advanced X–axis and Y–axis Maintenance


Advanced X–axis and Y–axis

CAUTION: To prevent damage to the cutterand/or fabric, only qualifiedoperators or maintenancepersonnel who have receivedGERBERcutter training shouldperform advanced X andY–axes procedures.

Roundway Bearings

The Y–axis roundway bearings are located onthe subplate where the cutter head ismounted. They should be adjusted so that thecutter head and subplate can not be physicallytwisted on the beam, and with no binding onthe Y–axis.



hex wrench, 1/4 in. 020945000

Adjust


2. Carefully tighten the bottom screws forthe roundway bearings (two screws foreach of four bearings).

CAUTION: To prevent scoring of theroundway, do not over tighten theroundway bearing screws.

3. Check that:

a) The subplate and cutter head can notbe twisted.

b) There is no binding on the Y–axis.


Squareway Bearings

The Y–axis squareway bearings are locatedon the subplate where the cutter head ismounted. They should be adjusted so that thesubplate and cutter head can not be physicallymoved up and down when force is applied tothe back of the subplate, and with no bindingon the Y–axis.


Adjust


2. Loosen the locking nut on the lowerbearing.

3. Adjust the eccentric with a screwdriveruntil the lower bearing barely makescontact with the squareway.

4. Tighten the locking nut.

5. Check that:

a) The subplate and cutter head can notbe moved by lifting from the back.

b) There is no binding on the Y–axis.


RoundwayBearings

SquarewayBearings



Spring Scale Tests

The spring scale tests are used to evaluate themechanical operation of the X and Y–axes.These tests can determine whether gearing, isset too tightly, lacks lubrication, or is bindingdue to misalignment or obstructions.

Note: The spring scale test can notdetermine if gearing is set too loosely.Use other X and Y–axes alignmentprocedures in this section to checkand adjust for loose gearing.


CAUTION: To prevent damage to the cutterand/or fabric, only qualifiedoperators or maintenancepersonnel who have receivedGERBERcutter training shouldperform advanced X andY–axes procedures.


spring scale 945500034

Test Y–axis


2. Move the cutter head to the farthest -Yposition on the beam.

3. Attach a spring scale to a support bracketon the cutter head.

4. Keep the spring scale held parallel to theY–axis while an assistant pulls the cutterhead across the entire length of Y–axistravel. The assistant should use the leastamount of force possible applied at asteady rate.

5. Verify that the spring scale does notexceed 6.8 Kg (15 lbs.). If it does:

− Check for any obstructions, wornbearings, or pulleys.

− Perform mechanical alignmentsdealing with the Y–axis covered inthis section.


Test X–axis


2. Move the cutter head to the farthest -Xposition on the table and to the centerposition on the beam.

3. Attach a spring scale to a support bracketon the cutter head.

4. Keep the spring scale held parallel to theX–axis while pushing the cutter headacross the entire length of X–axis travel.The assistant should use the least amountof force possible applied at a steady rate.

5. Check that the spring scale does notexceed 11.3 Kg (25 lbs.). If it does:

− Check for any obstructions, wornbearings, or pulleys.

− Perform mechanical alignmentsdealing with the X–axis covered inthis section.




Y–axis Drive Belt Tension

The Y–axis drive belt must be adjusted sothat when the servo motors are locked up andthe Y–axis is physically pushed or pulled, thebelt should not show signs of slack or contactthe outer edge of the pulley on the remoteside of the cutter when the Y–axis is slewedfrom one end of the beam to the other.

CAUTION: To prevent damage to the cutterand/or fabric, only qualifiedoperators or maintenancepersonnel who have receivedGERBERcutter training shouldperform the advanced X andY–axes procedures.

Adjust


2. Remove the end cap cover.

3. Loosen the two locking set screws on thesides of the adjusting screws for theY–axis belt pulley.

4. Adjust the screws in to tighten the belt orout to loosen the belt.

5. Slew the head back and forth to check thebelt skew. Repeat step 4 as needed.

With the cutter head slewed toward theremote side, you should be able to insertseveral fingers under the belt at a location60 cm (2 ft.) from the end cap cover andraise it 2.5 to 3.8 cm (1 to 1.5 in.).

7. Tighten the two locking set screws.


a) Install the end cap cover.


Replace


belt, Y–axis 041555006



3. On the remote side, loosen the twolocking set screws on the sides of theadjusting screws for the Y–axis beltpulley.

4. Remove the four screws that attach theY–axis belt to the subplate to which thecutter head is mounted (indicated).

5. Remove the belt from the adjustmentpulley and from the track that runs underthe beam.

6. Install the new belt.

7. Follow steps 4 through 7 of the procedurefor adjusting the belt.




LockingSet Screw

AdjustingScrew



Squaring the Beam

In order to correctly cut pieces from a markerthe beam must be square to the table.


CAUTION: To prevent damage to the cutterand/or fabric, only qualifiedoperators or maintenancepersonnel who have receivedGERBERcutter training shouldperform the advanced X andY–axes procedures.

Check

1. Run the Beam Square Test diagnostic tomake four cuts, one at each corner of animaginary square. See chapter 7.

2. The difference in the two measurementstaken diagonally across the imaginarysquare determines:

a) Whether the beam is square.

b) If it is not square, whether the first Xor second X–axis leads and by howmuch. Record this value for use instep 5 of the adjust procedure.

3. If the beam is not square within 1 mm(1/32 in.), adjust (square) the beam.

Adjust

1. Position the cutter head at the first X–axisside of the beam (nearest to the beamcontrol panel).

2. Press the EStop button on the beamcontrol panel to disable servos.

3. Position two C–clamps on the table rack,one on each side of the beam.


5. Remove the end cap cover. Use a pencilto scribe a mark for the current beamposition onto the roundway or rack.

6. Loosen the collar clamp on the torquetube pulley.

7. Refer to step 2b of the Check procedureand physically move the second X–axisside of the beam relative to the pencilmark:

− If the second X–axis side of the beamleads, then move the beam in the -Xdirection an amount equal to therecorded measurement.

− If the first X–axis side of the beamleads, then move the beam in the +Xdirection an amount equal to therecorded measurement.

8. Tighten the coupling clamp on the torquetube pulley.

9. Enable servos and then run the BeamSquare Test diagnostic again to check theadjustment.


a) Install the end cap cover.


Work Surface Maintenance


TableThe cutting table provides a work surface forcutting material. Major assemblies of thetable include the beam, bristle work surface,filtration, vacuum generator, and materialhandling. TCW systems also have assembliesrelated to the traveling platform.

Table assemblies covered in this section arelisted in the table below.

Assembly See Page

Work Surface 130

Work Surface Cleaner 132

Roundways and Racks 133

Filters 134

Vacuum Assembly 135

Material Handling Systems 138

Platform 141

Work Surface

The BRISTLE SQUARES form the worksurface of the cutter. They are small, plasticsquares with bristles on one side and aperforated base on the other. The BRISTLESQUARES fit into aluminum slats on TCWand ZVC systems and in plastic grids onStatic systems.

BRISTLE SQUARES last longer if you cleanthem regularly and move them to differentpositions on the table to spread wear moreevenly.

Inspect

1. If your system is a TCW or ZVC do thefollowing:

a) Turn power on at the table controlpanel.

b) To access all portions of the worksurface, set the Conveyor Mode toManual.

c) Jog the conveyor to move unexposedportions of the bristle work surfaceinto view.

2. Inspect the BRISTLE SQUARES for lint,broken bristles, and other cutting debris.Clean them if necessary.

3. Inspect the BRISTLE SQUARES foruneven wear, scarring, or creasing.Rearrange the BRISTLE SQUARES ifnecessary. Sometimes the squares may bedamaged beyond repair; this could be asign of another problem. If you see suchdamage, call your Field Servicerepresentative.

Work Surface Maintenance


Clean

1. Vacuum the BRISTLE SQUARES toremove debris.

2. For TCW or ZVC systems, jog theconveyor to reach unexposed portions ofthe bristle work surface.

Remove/Rearrange

To rearrange BRISTLE SQUARES forTCW or ZVC systems:

a) Working on one slat at a time, set aclamping pliers deeply into the bristleand pull the square out of the slat. Seebelow.

b) Remove the other squares in this slatby hand.

c) Move the square to a part of the slatthat is less worn.

d) Jog the conveyor to reach unexposedportions of the bristle work surface.

To rearrange BRISTLE SQUARES forStatic systems:

a) Locate the first grid that you want toremove.

b) Set one clamping pliers deeply intoone side of the grid. Set anotherclamping pliers deeply into the bristleon the opposite side of the grid.

c) Remove the grid. You can remove theremaining grids by hand.

d) Position the grid on a portion of thecutting table that is less worn.

Install

Install the BRISTLE SQUARES in thework surface of TCW and ZVC systemsby snapping them into place in the slats.

Install the BRISTLE SQUARES in thework surface of Static systems:

a) Replace all but the last BRISTLESQUARE grid in the table.

b) Place the bristle locating over theedges of the bristle surrounding theremaining grid.

c) Snap the remaining grid into placeand remove the bristle locatingguides.


bristle locating guides 023678000

bristle locating guides 023679000

LocatingGuides

Work Surface Cleaner Maintenance


Work Surface Cleaner

TCW systems have a mechanical worksurface cleaner. This is an auger located onthe take–off end of the table. The augerrotates through the bristle work surface that isnot exposed. The lint and debris that fallsfrom the auger collects in a basin at the take–off end of the system. You must clean thisbasin periodically.

Inspect


2. Open the access doors at the take–off endof the TCW table.

3. Check the basin for accumulated lint andcutting debris. Clean the basin, ifnecessary.

WARNING! Avoid breathing in lintcollected in the basin of thework surface cleaner. Wear amask suitable for cleaning lint.

Clean

1. Vacuum out the lint and debris that hascollected in the basin.

2. Inspect the auger for damage of any kind.If you notice any cracks, heavy scoring, orother signs of damage, call Field Serviceimmediately.


Gear Box

The gear box for the work surface cleaner islocated on the remote side of the cutter at thetake–off end of the table. Periodically, checkthe fluid level in this gear box. The third timeyou check the fluid level, drain and replacewith SAE 600 weight oil.


Pillow Block Bearings

There are two pillow block bearings locatedinside of the work surface cleaner basin, oneon each side of the cutter. Open the accessdoors to lubricate these bearings.


GearBox

CoverAccessDoors

Roundways and Racks Maintenance


Roundways and Racks

The beam travels the length of the cuttingtable on roundways and racks. The beam cannot travel smoothly if the roundways andracks are excessively dirty or damaged.

Roundways

The roundways run the length of the cuttingtable. Motors for the beam drive the beamalong the roundways. The beam can not travelsmoothly if the roundways are damaged ordirty.

Inspect the roundways for abrasions andscoring. Contact your Field Servicerepresentative if you notice any. Inspect theroundways for built–up dirt and lint. Clean, asneeded.


Racks

The racks are toothed tracks that run thelength of the cutting table. Motors and gearsin the beam drive the beam along the racks.The beam can not travel smoothly if the teethof the racks are damaged or dirty.

Inspect


2. Check the racks for damaged teeth,scoring, or abrasions. If you see any ofthese conditions, call your Field Servicerepresentative.

3. Inspect the racks for built–up dirt and lint.

CAUTION: Use care not to damage the teethof the rack. Clean only whenabsolutely needed.

Roundway

Rack

Filters Maintenance


Filters

The GERBERcutter uses filters as part of thevacuum system to trap lint and moisture fromthe work environment.

Vacuum Filter

The vacuum filter canister for S91 systems isa drum with a filter inside. The vacuum filtertraps lint and other debris from the table top.Keep the filter clean to prevent a decrease invacuum.

Note: The on–screen gauge in the C200MTprogram will alert you to decreasedvacuum pressure.

For a TCW system the drum is located at thetake–on end of the table under the front ramp.For ZVC and Static systems, the drum ismounted in–line between the externalvacuum assembly and the cutting table.


filter element, Static or ZVC 022810000

filter element, TCW 460500102

WARNING! Avoid breathing in lintfrom the filters. Wear a masksuitable for cleaning the filter.

CAUTION: Do not use compressed air toblow out the drum as cuttingdebris may work its way into theturbine or blower and causedamage.


Stack Filter

The stack filter is located in a canister on theexhaust stack. For TCW systems, the stack ispart of the mast at the take–on end of thetable. For Static and ZVC systems, the stackis located at the external vacuum assembly.

The stack filter traps debris which mightdamage the vacuum generator. You mustkeep this filter clean to ensure the properworking of the vacuum generator.



filter element, stack 460500037

WARNING! Avoid breathing in lintfrom the filters. Wear a masksuitable for cleaning the filter.

Cover

Filter

Vacuum Assembly Maintenance


Air/Reducer Filter

On TCW systems, there are one or moreair/reducer filters located on the exhaust stackand mast of the table. These filters improveair flow. If they get clogged, air pressuredrops.

CAUTION: Before opening the drain valve,reduce air pressure manually byturning the cap. Dirty liquid mayspray and stain material.


Vacuum Assembly

The vacuum generator assembly includes thevacuum generator and the vacuum generatormotor. The motor drives the turbinegenerator.

In all TCW systems and some ZVC andStatic systems, the motor drives a turbine orblower by use of a single wide or multiplenarrow drive belt(s). In most ZVC and Staticsystems, a coupling connects the motor and ablower.

Cover

The vacuum generator assembly for TCWsystems is located under the front ramp or(take–on cover). This ramp must be removedto perform maintenance procedures such aslubrication and tensioning of the belt(s).

External vacuum assemblies for Static andZVC systems have either a jack shaft cover ora coupling guard that must be removed toperform maintenance procedures.

Remove

1. Turn off power at the C200 controller.For Static and ZVC systems, also turn offpower at the external vacuum assemblyand at the table control (or lay pullercontrol) panel.

2. Depending on your system:

− For TCW systems, remove mountingscrews and shims at both sides of thefront ramp. With the help of anassistant, lift off the cover.

− For Static or ZVC systems with aHoffman blower and coupling guard,remove four screws from the couplingguard. Lift off the coupling guard.

− For Static or ZVC systems with aSpencer turbine, unlatch threefasteners on the jack shaft cover.Lower the cover and move aside.

Install

1. Depending on your system:

− For TCW systems, with the help of anassistant, lift the cover into place.Reposition the shims. Install andtighten the mounting screws.

DrainValve

Cap



− For Static or ZVC systems with aHoffman blower and coupling guard,reposition the coupling guard. Installand tighten four screws for thecoupling guard.

− For Static or ZVC systems with aSpencer turbine, reposition the jackshaft cover. Latch the three fasteners.


a) Turn power on at the external vacuumassembly, if applicable.


Motor and Generator

Lubricate the motor and generator regularly.Check belt tension or coupling alignmentbetween the motor and generator.

Maintenance procedures related to thispart of the cutter are covered in the 960hour maintenance schedules.

For systems with a Spencer turbine or anHoffman blower with pillow block assembly,you need to check belt tension regularly andadjust belt tension as needed. For systemswith a Hoffman blower coupled to the motor,you need to check coupling alignment.


Drive Belt Tensioning

Drive belt(s) between the motor and generatorcan stretch, fray, or wear. Adjust belt tensionor replace as needed.


Adjust/Replace


belt, 50 Hz (4 per unit) 180078008

belt, 50 Hz (5 per unit) 180500038

belt, 60 Hz (5 per unit) 180500006


2. As required, remove the front ramp orjack shaft cover to access the drive belt(s).

3. Adjust or replace as follows:

a) Loosen the nuts on four bolts thatsecure the generator motor.

b) If replacing a belt, remove all belt(s).Install new belt(s).

Note: All belts must be replaced,even if only one is worn orfrayed.

c) With the help of an assistant,reposition the motor and then tightenthe nuts.

d) Check belt tension again and comparethe deflection to the manufacturer’sspecs.



4. If required, replace the front ramp or thejack shaft cover.


a) Turn power on at the external vacuumassembly.


Coupling Alignment

For motors coupled to an Hoffman blower,the coupling between the motor and Hoffmanblower must be checked for alignmentregularly. It is possible to check couplingalignment when the assembly is cold.However, the hot alignment method, whichchecks after the unit has run for at least anhour, is more accurate.



Align (cold system method)

1. Make sure the C200 controller is turnedoff. For Static and ZVC systems, alsomake sure the power is off at the externalvacuum assembly and at the table control(or lay puller control) panel.

2. Remove the coupling cover.

3. Adjust alignment as follows:


b) Place a straight edge across the huband verify with a feeler gauge that thecenterline for the shaft of the motor ishigher than the centerline for the shaftof the blower by the specified amount.The spec for the cold system methodis printed on a plate affixed to theblower.

c) Use shims as required. Then tightenthe four bolts.




Align (hot system method)

1. Run the vacuum system for an hour ormore.


3. Remove the coupling cover.

CouplingGuard

Motor

Blower

From Cutter

Material Handling Systems Maintenance


4. Adjust alignment as follows:


b) Place a straight edge across the hub.The straight edge should lay flat.

c) As shown above, measure thedistance between the outside hubs atfour places, each 90 degrees from theprevious location. If the distancebetween the four measurements is notwithin 0.40 mm (1/64 in.), then go tostep 5.

5. When the system is cold, use shims toraise or lower the motor, as required. (Seethe cold system method.)

6. Tighten the four bolts.




Material Handling Systems

Material handling systems depend on the typeof cutter. These may include: the clamp bar,resealer, conveyor, or motorized lay puller.

Clamp Bar

On TCW systems, the clamp bar works withthe conveyor to pull material onto the cuttingtable. The air cylinders that raise and lowerthe clamp bar require cleaning and lubricationto work smoothly.


Resealer

If your cutter has the resealer option shownbelow, routine maintenance proceduresinclude lubricating the air cylinder rods andchecking that the bar moves up and downevenly.


ResealerBar



Conveyor Drive Gear Box

The gear box for the conveyor drive is locatedat the take–on end of the cutter. Periodically,check the fluid level in this gear box. Thethird time you check the fluid level, drain andreplace with SAE 600 weight oil.


Conveyor Drive

TCW and ZVC systems use a conveyor tomove material on and off the cutting table.Potentiometers for the drive motor that jogsthe conveyor can be aligned to accommodatea variety of spreads.

WARNING! High voltagesexist inside the C200 controller,vacuum and platform electricalenclosure and the cutting table.There are no operator–serviceable parts inside. Onlyqualified personnel shouldperform maintenance on theseassemblies. Contact yourService Technician in case of aproblem. Failure to follow theseinstructions could cause injuryor death.


Align

1. At the platform control panel, set theConveyor Mode to Manual.

2. For ZVC systems, remove the take–onend cover. For TCW systems, open thedoor to the vacuum and platformelectronics (shown below).

3. Jog the conveyor to start moving thespread onto the table.

4. Adjust the potentiometers for the Baldordrive as follows:

a) Set an initial torque, T1, for ramp upspeed.

b) Set a normal operation speed, T2(Range for torque is 0 to 100%).

c) Set the time for ramp up, A, from 0 toT1 and from T1 to T2. (Range for Ais 0 to 7 sec.)

These settings should result in the shortestand smoothest acceleration capable ofpulling a production spread onto thecutting table.

Note: Refer to the documentation that camewith the drive motor.

5. Position a typical spread on the spreadingtable. Check the alignment by jogging theconveyor; repeat step 4 as required.



Lay Puller Gear Box

The gear box for the lay puller drive islocated under the cutting table. Periodically,check the fluid level in this gear box andreplace with SAE 600 weight oil.


Lay Puller Drive

Static systems use a motorized lay puller tomove a spread onto the take–on end andalong the length of the cutting table.Potentiometers for the drive motor that jogsthe lay puller can be aligned to accommodatea variety of spreads.

WARNING! High voltagesexist inside the C200 controller,vacuum and platform electricalenclosure and the cutting table.There are no operator–serviceable parts inside. Onlyqualified personnel shouldperform maintenance on theseassemblies. Contact your GGTService Technician in case of aproblem. Failure to follow theseinstructions could cause injuryor death.


Align

Note: Do not refer to the documentation forthe drive motor when settingpotentiometers. Use the followingprocedure instead.

1. Initial settings for the Reuland drive are:

− Turn the torque potentiometer (pot)fully counter clockwise.

− Turn the time pot fully clockwise.

2. Jog the lay puller to start moving thespread onto the table. Adjust the torquepot clockwise until the lay puller bar justbegins to move.

3. Again, jog the lay puller and readjust thetorque pot so the maximum delay beforethe bar begins to pull is 1 or 2 seconds.

4. Position a typical spread in the lay puller.Repeat steps 2 and 3.

5. Adjust the time pot counter clockwise(decreasing) to attain the shortest andsmoothest acceleration acceptable forpulling a production spread onto thecutting table.

Platform Maintenance


Platform

S91 TCW systems travel on rails betweenspreading tables. Power is transferred throughan overhead cable trolley.

Platform drive maintenance includes:

• Lubricating the platform drive chain,sprocket bearings, and cam rollerbearings.

• Checking fluid levels in the platformdrive gear boxes on two wheelassemblies.

• Lubricating platform wheel cam rollerbearings and shaft bearings on fourwheel assemblies.

Overhead cable trolley maintenance includescleaning and lubricating the roller bearings.


WheelAssembly

Platform DriveWheel

Assembly

OverheadCableTrolley

Platform Maintenance


Chapter 7 Troubleshooting Page 143

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The C200MT cutter control software provides the following features to assistyou in troubleshooting your GERBERcutter.

• Error messages.

• Diagnostics.

These features are explained briefly in this chapter. For more information, referto the C200MT Software User’s Guide.

Additional troubleshooting tools available currently or in the near future include:

• Training (CBT) on CD–ROM.

• Service Parts on CD–ROM.

• Applications manual.

See sections later in this chapter. Contact GGT Product Support or your localField Service office for information on availability and how to obtain copies.

Product Support

If a condition still exists after troubleshooting, call your GGT Product Supportor local Field Service office for help. Within the United States and Canada, call800-999-1448. Otherwise, call you local Field Service office. Have your servicecontract number ready.


Error Messages

The GERBERcutter displays an error message dialog box when it detects anerror condition. The system numbers these error messages for easy reference.The first digit of the error number defines the error class. The error classes rangefrom 1 to 4, with class 1 being the least severe. PreProcessor error messages donot have an error number.

Error Message Type Error Number Range

Class 1 FEP 1000-1999

Class 1 MCC 1000-1999

Class 2 2000-2999

Class 3 3000-3999

Class 4 4600

This section gives a brief overview of the types of error messages, samples ofmessages, and recommended solutions. A complete list of errors and solutions isincluded in the C200MT Software User’s Guide.


Class 1 FEP Errors

Class 1 FEP (workstation PC) errors relate to conditions with the cut file. Whena class 1 error occurs, the system stops cutting. To resume cutting, see therecovery procedures in chapter 3.

The following table gives some keywords you might find in this type of errormessage, actual samples of class 1 FEP error messages, and possible solutions.Simple solutions, such as editing cut data or restarting the program, should betried before contacting Field Service.

Note: Before trying solutions that involve reloading software, refer to theC200MT Software User’s Guide for a complete listing of messagesor call Field Service.

Message Keywords Possible Solutions Sample Messages

illegal; invalid; not found;max allowed; converting

file; character; code; data;point; block; stops; SBITE

Edit or regenerate cut datafile. Change parametersettings. Reposition thespread.

1002 Illegal character inlogical block

1429 SBITE: Can’t bitewithout reorder

wrong number; too many;out of range; overrun; notresponding; failed

parameter; queue; serialline; buffers; PC controller\SYSFILES\xxx.INT

Quit the C200MTprogram, turn off thepower, and restart. CallField Service if conditionpersists.

1105 Wrong number ofparameters: TR

1302 Overrun on serial 2line

offtable Move the origin. Check thecut file format. Check thatthe cutter head and beamare not too close to thelimit switches.

1017 Offtable -X

timeout; not found

\SYSFILES\ENGLISH\xxx.INT

Quit the C200MT programand reload the C200MTsoftware. Call FieldService if conditionpersists.

1410 Timeout Errorrequesting input status

1418 \SYSFILES\ENGLISH\ DG23.INTnot found


Class 1 MCC Errors

Class 1 MCC errors relate to conditions with the commands that the MotionControl Computer (MCC) sends to the cutting table. When a class 1 MCC erroroccurs, the system stops cutting. To resume cutting, see the recovery proceduresin chapter 3.

The following table gives some keywords you might find in this type of errormessage, actual samples of class 1 MCC error messages, and possible solutions.Refer to the C200MT Software User’s Guide for a complete listing of messages.

Message Keywords Possible Solutions Examples

initialization not completed

limit switch; knife motor;beam control panel

Check cable connections,loose wiring, and fuses.Check air pressure. Checklimit switches.

Change parameters.Initialize the cutter. Turnknife motor on. Slewbeam.

1006 Error occurred whilehoming (initializing)

1008 C–axis could not getoff limit switch

1423 Y limit switch active

up; down; position; not on

tool; bite sensor; knife;drill; auxiliary drill;sharpener solenoid

Use Input Output Test(DG23) diagnostic tocheck for signal.

1021 Bite Sensor not down

1107 Drill not up

failed; rejected; invalid;logging; aborted; notoriented

number; memory block;coefficients; data; encoder;C–axis


1009 Encoder reset failure

1315 Bad piece number

1619 Error setting XDynamic coefficients


Class 2 Errors

Class 2 errors relate to conditions resulting from communication and dataprocessing. When a class 2 error occurs, the system displays an error message.To resume cutting, see the recovery procedures in chapter 3.

The following table gives some keywords you might find in this type of errormessage, actual samples of class 2 error messages, and possible solutions. Referto the C200MT Software User’s Guide for a complete listing of messages.


following error; level toohigh

bite; conveyor; vacuum

Quit the C200MTprogram. Check sensor ormechanical condition ofthe system. Call FieldService if conditionpersists.

2000 X following error

2552 Vacuum level toohigh to bite (ZVC)

overflow; invalid; toomany; no more; bad

vacuum; parameter; BGLASCII


2330 Non-numeric char inASCII to integerconversion

2357 Bad parameter table

failure

KI

Use the KI Calibration(DG20) diagnostic tocalibrate the KI sensor.Call Field Service ifcondition persists.

2006 KI sensor failure

knife down Edit cut file. Changeparameter.

2350 Knife down movelength exceeds max


Class 3 Errors

A class 3 error is a serious hardware error. Cutting halts. To resume cutting, seethe recovery procedures in chapter 3.

The following table gives some keywords you might find in this type of errormessage, actual samples of class 3 error messages, and possible solutions. Referto the C200MT Software User’s Guide for a complete listing of messages.


offscale Check data format andregenerate cut file. Setorigin closer to theinitialization point ofthe table.

3400 Offscale +X

unknown; failed

BCC; beam control panel;servo; emergency stop

Check cabling to BCC.Check power to the servodrive.

Fix the EStop condition.Press the Servo Powerbutton.

3010 Unknown BCC errordetected by 68K

3237 C servo drive failed

following error; invalid;unknown; excessive

conveyor; knife

Quit the C200MTprogram. Checkmechanical condition ofthe system. Call FieldService if conditionpersists.

3000 X max followingerror

3810 Excessive KnifeCurrent

invalid; error sending

sharpen; servo


Class 4 Errors

A class 4 error is a serious non–recoverable C200 controller error caused byeither a hardware or software condition. Power down the system, then power upagain. If the error appears again, call Field Service. To resume cutting, see therecovery procedures in chapter 3.


Diagnostics

Diagnostics included in the C200MT program provide tools which can be usedby the person in your company responsible for GERBERcutter maintenance orby Field Service to ensure cutter performance. Diagnostics used for routinemaintenance and covered in this section include:

• Input Output Test (DG23).

• KI Calibration (DG 20).

• C Home to System Zero.

• Heel to Heel Cut Test.

• Beam Square Cut Test.

• Knife Offset Setup Cut Test.

Note: For detailed information about diagnostics that are not covered inthis section, refer to the C200MT Software User’s Guide.

Diagnostic Use To

Input Output Test (DG 23) Check MCC input and output signals.

Servo I/O Test (DG 16) Read and zero selected encoders; control output voltage ofdigital–to–analog converters; display input voltage for analog–to–digital converters.

KI Calibration (DG 20) Set Knife Intelligence deflection voltage.

C Axis Angle Rotate the C–axis to any angle.

Single Step Run in single step mode to check cut file data.

Continuous Run Run one cut file continuously in the same place.

Display Bite Adjust Values Display the difference (error) between how much the conveyorand the beam move during a bite.

Position Info Calculate change in distance from current position to origin.

Conveyor/CTOT Speed Calibrate Calibrate conveyor and CTOT speeds.

C Home to System Adjust this knife setting and command the knife to plunge fourtimes in a straight line.

Stepsize Setup Calculate new stepsize settings for the X and Y–axes.

Zone Vacuum Exerciser Test, setup, or troubleshoot hardware for the vacuum zonecontrol.


Diagnostic Use To

Cut Tests

Multiple Horizontal Lines Check C–axis mechanical alignment

Multiple Vertical Lines Check C–axis mechanical alignment.

Multiple 45 Degree Lines Check X, Y, and C–axes electrical alignments.

50" Square Test Square the beam.

Concentric Circles Test cutting.

Beam Square Test Square the beam.

Heel to Heel Test Check knife mechanical alignment.

Yaw in X Test Check C–axis mechanical alignment in X–axis.

Yaw in Y Test Check C–axis mechanical alignment in Y–axis.

10" Square Center drill hole.Check drill placement.

Geometric Shapes Test cutting.

5' Bite Test Test a conveyorized GERBERcutter.

Knife Offset Setup Check knife alignment.

Drill 1 Offset Setup Check main drill alignment.

Drill 2 Offset Setup Check auxiliary drill alignment.

Pen Offset Setup Check pen alignment.

Software Diagnostics (Used for software development only)

Path Intelligence

Calibration Calibrate PI.

Watch Forces Check XY forces on the knife blade.


Selecting Diagnostics

Choose the commands in the Diagnostics menu to access diagnostics.Additional diagnostics are available in the Cut Tests, Software Diagnostics, andPath Intelligence submenus.

Input Output Test (DG 23)

This diagnostic can be used to test individual motors, switches, lights, and othercomponents. Only use this diagnostic when told to by this manual or by FieldService.

To run diagnostic

1. Turn on the GERBERcutter and run the C200MT program.

2. Optional — Enable servo power and then initialize the cutter.

3. From the Diagnostics menu, click Input Output Test (DG 23).

The system displays a test screen. On this screen, active shows asgreen; inactive shows as red.

WARNING! Stand away from moving parts on yourGERBERcutter when using this diagnostic. Injury ordeath may result if you are in the path of GERBERcutterparts when they move. Depending on which control youare testing, part of the GERBERcutter may move. Thiscan be, but is not limited to, the knife blade, drill,conveyor, and other mechanical parts.


4. To test an output signal, use the arrow keys or pointing device tohighlight the signal that you want to test. Then hold down the Ctrl keyand press the Space bar.

5. To test an input signal, you will need to use a cutter component. Forexample, press a button.

The listed signal changes either from 0 to 1 or 1 to 0. The actualcomponent on the cutter you are testing becomes active or inactive.

Note: On this screen, active shows as green; inactive shows as red.

6. After you finish testing components, press Esc or click the Exit I/ODiagnostic button.

KI Calibration (DG 20)

Use this diagnostic at the beginning of each shift to calibrate the KnifeIntelligence deflection voltage sensor (if the cutter can utilize KI).

Note: To check if calibration is required, first use the Null KI command(see chapter 5).


right angle handle hex key set 944022402


To run diagnostic


2. On the presser foot bowl assembly, loosen the clamping screw thatlocks the transducer adjusting screw. See chapter 6.

Note: For this diagnostic, it is not necessary to remove the presserfoot bowl assembly (as shown below for clarity purposesonly).

3. Enable servo power.

4. From the Diagnostics menu, select KI Calibration (DG 20).

5. Adjust the transducer screw until the output voltage is at, or near,zero (0).

6. Tighten the clamping screw to lock the transducer adjusting screw.

7. When finished, press Esc or click the Exit DG20 button.

8. Use the Null KI command to null Knife Intelligence (see chapter 5).

ClampingScrew


C Home to System Zero Diagnostic

The C Home to System Zero diagnostic allows you to adjust knife yaw andcommand the system to plunge the knife four times in a straight line.

To use C Home to System Zero


2. Open Parameter Manager and use the Advanced button to enter apassword and change access level to Supervisor or Field Service. Referto the C200MT Software User’s Guide.

3. Place a large square of paper on the cutting surface. Position the cutterhead over the paper.

4. From the Diagnostics menu, select C Home to System Zero.

5. In the dialog box, type the number of degrees to adjust the knifesetting.

6. Press the Plunge Knife 4 Times button.

7. After the knife has plunged four times, compare the cuts to theexample shown below and in the dialog box. Make any necessaryadjustments.

8. Reposition the head over the paper. Repeat steps 4 through 7 untilsatisfied with results.

9. Initialize the cutter to make your changes effective.

10. When finished, press Enter or click the OK button.

11. When prompted, you can choose to save changes to all setups.

12. If you clicked Yes in step 11, the system prompts how many setupswere changed. Press Enter or click the OK button.


Running Cut Tests

A Cut Test is actually just a marker designed to check a specific cutteroperation. Run Cut Tests as you would any marker, replacing the spread with apiece of paper. Specific steps required for a Cut Test diagnostic and the expectedresults are explained in each topic.

To run Cut Tests

1. Run the C200MT program.

2. Enable servo power.

3. Initialize the cutter.

4. Position paper and plastic on the table. See each diagnostic for thespecific paper size to use.

5. Turn on the vacuum.

6. Slew the cutter head to the lower left corner of the paper.

7. On the beam control panel do all of the following:

− Press the ORIG button.

− Set CUTTING SPEED to 10, unless otherwise noted.

− Set KNIFE to ON.

8. From the Diagnostics menu, choose Cut Tests. Then select theappropriate diagnostic.

9. Press the Start button to run the diagnostic. The GERBERcutterdisplays the status screen while the diagnostic is running.

10. When processing is complete, at the beam control panel do all of thefollowing:

− Set KNIFE to OFF.

− Press the VAC ON/OFF button.

11. Slew the cutter head out of the way, unless otherwise noted.

12. Check the results as explained in the topic for each diagnostic.


Beam Square Test

Use this Cut Tests diagnostic to check that the beam is square with the cuttingtable. In this diagnostic, the cutter plunges the knife at each corner of a square. Ifthe measurements from corner to corner are the same, neither end leads as thebeam travels along the table and the beam is square. If the one end leads,perform the maintenance procedure on page 129.

To run the diagnostic

1. Run the Cut Tests diagnostic as (see page 155) except:

a) Place a piece of paper at least 1.5 m (60 in.) square and preferablylarger on the table. This diagnostic must be rerun after making anyadjustments.

b) Before initializing the cutter, turn Run Time Biting OFF.

2. To check results, first measure a diagonal line from top right tip tobottom left tip of the knife plunges. Then repeat from top left tip tolower right tip to get the second measurement. Each line should be 160cm (63 in.).

3. Compare the measurements with those in the following table.

Measurement Indication Action

Equal to within 1.0 mm(0.03 in.)

The beam is square. None

First is greater than second The beam is not square.The +Y end of the beamleads the -Y end.

Use the differencebetween thesemeasurements to adjustbeam alignment.See page 129.

Second is greater than first The beam is not square.The -Y end of the beamleads the +Y end.

Same as above.

First Measurement

Second Measurement


Heel to Heel Test

Use this Cut Tests diagnostic to check the mechanical alignment of the knife inthe C–axis. The knife must be properly aligned for accurate cutting. In thisdiagnostic, the system plunges the knife twice so that alignment can be checked.


1. Run the Cut Tests diagnostic as normal (see page 155) except:

a) Place a piece of paper 0.5 m (20 in.) square or larger on the table.

b) After initializing the cutter set Knife speed to 2,500 rpm for all S91systems.

CAUTION: Knife speed must be set as indicated above to simulatethe knife load caused by cutting a spread and to ensurethat results of this diagnostic are accurate.

c) Set Cutting speed to 1.

2. To check results, compare your test knife cuts with the drawing shownbelow.

Good Unacceptable

Measurement

(b)(a)

a) If results are good, go to step 3.

b) If the knife alignment is unacceptable, your trained GERBERcuttermaintenance person can adjust knife alignment using the procedureon page 111. Otherwise, call Field Service.

Note: A slight negative offset is beneficial under certain cuttingapplications. Contact Field Service for recommendations andlimitations.

3. When alignment is correct, measure the heel–to–heel distance. If thismeasurement falls outside the 2.7 to 14.3 mm (0.5 to 0.56 in.) range,your trained GERBERcutter maintenance person can adjust knifealignment using the procedure on page 111. Or, call Field Service.


Knife Offset Setup

Use this Cut Tests diagnostic to check that the cutter is using the correct valuefor knife offset. Knife offset is the location of the knife blade relative to theorigin light. If the system is using the wrong value for knife offset, cuts will notbe made in the correct location.

Note: This diagnostic should be used whenever the laser light or head ischanged.


1. Run the Cut Tests diagnostic as normal (see page 155) except place apiece of paper 1.5 m (60 in.) square or larger on the table.

The cutter positions the knife at, or near, the origin and executes aknife down cycle.

2. After cutting stops, the Systems Message box prompts that processingis complete. Use the Move to Origin command.

3. To check results, make sure that the origin light shines exactly on theintersection of the horizontal and vertical lines. If it does not, do one ofthe following:

− Continue with steps 4 through 6.

− Call Field Service.

4. Use the Position Info diagnostic (refer to the C200MT Software User’sGuide) to determine the exact location.

5. Make appropriate changes to the Offset in X - Knife and Offset inY- Knife parameters in the System Setup category.

6. Reorigin and repeat this diagnostic to check your changes.


Training (CBT)

GERBERcutter computer based training (CBT) is designed to work right onyour cutter. More than just training, the GERBERcutter Training CD includes:

• Basic operation modules.

• Maintenance modules.

• Application wizards.

• Navigator.

Video and animation, along with text, guides you step–by–step through basicoperations and complex maintenance procedures. Application wizards offersuggestions to resolve conditions such as pushing or fusing. The Navigatorshows you at a glance the types of information available and jumps right to thespecific information you need. Ask your local Sales office about availability.

To run Training (CBT) at your cutter

1. Insert the CD–ROM in the disc drive.

2. From the Help menu, select Training (CBT) .

The Training software must be installed on your cutter in order to access thisprogram. Refer to installation information in the CD–ROM insert.

Service Parts

The GGT Service Parts documentation on CD–ROM provides the latest partsinformation for your GERBERcutter. Assembly drawings in exploded view areprovided with indexes that identify names and part numbers. Drawings aregrouped by the type of GERBERcutter. Categories within each type are Head,Beam, Electrical, and Installation. There is also a listing for all GERBERcuttersof consumables (spare parts), such as drill bits, knife blades, and belts.

Information is stored in Adobe Acrobat PDF format for easy access. Features inthe Acrobat reader include:

• Zoom for enlarging drawings.

• Search for finding a part by name or number.

• Print for printing out assembly drawings or part number lists.

Refer to the installation instructions that come with the CD when installing theParts documentation and the Acrobat reader.


CAM Applications

Flexibility within the C200MT program allows you to set up yourGERBERcutter based on differences in patterns, materials, and types ofmanufacture. When your GERBERcutter was first installed, your Field Servicerepresentative or trainer customized setup files for your manufacturing needs atthat time. To achieve optimal cutting performance for a different applicationyou should:

• Prepare the cut file data for automated cutting. Consider fabric, size ofthe pieces, and cutting sequence. See below.

• Select the most appropriate preset setup available in the C200MTprogram. Your selection should be based on fabric hardness, porosity,tendency to fuse, and ply height. Refer to the C200MT Software User’sGuide.

• Customize vacuum settings, knife sharpening, and motion controlparameters for this setup. See the next page.

Automated cutting concepts are explained briefly below. For detailedapplications information, ask your Field Service representative about theavailability of the CAM Applications manual.

Automated Cutting Concepts

The GERBERcutter is an efficient, computer aided manufacturing (CAM)system. Computer aided design (CAD) systems provide instructions in a cut fileto control the cutting system. The GERBERcutter executes those commands.Parameters in the C200MT program determine exactly how those commands areexecuted.

To improve cutting results consider the following concepts.


Data Preparation

Preparation of data for a GERBERcutter differs from hand cutting in that specialconsideration must be given to the pattern pieces and the material being cut. Anoperator cutting by hand intuitively compensates for a different fabric or tatteredcorners on a pattern piece.

Because the GERBERcutter simply follows CAD instructions, the patternmaker, digitizer, and marker maker must give consideration to some of thethings mentioned below. Remember, automated cut quality is directly related tothe CAD instructions.

Pattern Pieces — Before pattern pieces are digitized and stored, it is a goodidea to answer the following questions based on the cutting results desired.

− Are slit, V, or both notch types going to be used?

− Is it permissible to miter corners?

− Is there an added buffer on the pattern template to compensatefor hand cutting inaccuracy? If so, is it still needed?

If existing pattern pieces are torn, wrinkled, or frayed, redefine making surecorners are accurate, crisp, and clean with straight lines and smooth curves.

Digitizing — Always define an accurate grain line. If the grain line is off inrectangular pieces, the parts will not nest with true common lines.

Marker Making — The marker maker should consider the placement of largeand small pieces (see Vacuum Hold Down section).


Vacuum Hold Down

The GERBERcutter relies upon a vacuum system to compress and stabilize thematerial to be cut. The size of cut pieces, material porosity, and cutting sequenceaffect the performance of the cutting system. You can customize a setup bychanging parameters in the Vacuum Systems category. Refer to the C200MTSoftware User’s Guide.

Regularly scheduled maintenance of the vacuum system ensures optimummechanical performance of the GERBERcutter. See chapter 6.

Knife Sharpening

Material content (i.e. natural or synthetic fibers, coatings, etc.) and ply heightsdetermine knife sharpening requirements. You can customize a setup bychanging parameters in the Sharpen Parameters category. Refer to the C200MTSoftware User’s Guide.

Regularly scheduled maintenance of the sharpener assembly ensures optimummechanical performance of the GERBERcutter. See chapter 6.

Motion Control

Quality requirements, material, and type of manufacture must be consideredwhen optimizing the performance of the GERBERcutter.

The C200MT program has a built–in knowledge base and is flexible enough tomeet the needs of Aerospace, Apparel, Automotive, Furniture and many otherindustrial applications. For example, if cutting tubular goods you may want touse the Clipping Window or Centerline Origin features. If cutting narrowmarkers, Marker Stacking may speed throughput. Refer to the C200MTSoftware User’s Guide.

Glossary Page 163

*ORVVDU\*ORVVDU\

axis

An imaginary line used to describe movement and location on the cutting table.The GERBERcutter has three axes: X (parallel to table length), Y (parallel to table width), and C(knife direction).

backlash

The space between two gears or a gear and its rack.

beam control panel (BCP)

A terminal that lets you control the cutter head and beam assembly from the cutting table.The computer that processes input from the beam control panel is called the BCC.

bite feeding

A feature on TCW and ZVC systems that matches cutter head movement with conveyor movement,permitting automatic cutting of a long spread. The spread is cut in sections that fit on the cuttingtable surface. Each section is called a bite.

BRISTLE SQUARE

Squares of molded bristle that plug into conveyor slats on TCW and ZVC systems or into grids onStatic systems. They form a work surface for cutting material.

C200 controller

The command center of the GERBERcutter.

C–axis

An imaginary straight line that the knife rotates about.

circuit breaker

A switch that automatically interrupts an electric circuit.

command

A request entered at a terminal, such as the operator workstation, to perform a function.

config

See setup.

conveyor

Moving work surface on TCW and ZVC systems made from aluminum slats and covered withGerber BRISTLE SQUARES.

cursor

A pointer that you see on the monitor screen of your operator workstation. Use the pointing deviceto move the cursor.

Glossary

cut file

A computer data file that tells the GERBERcutter how to cut out pattern pieces in a marker from aspread.

Cutter Info Database (CIDB)

An optional report generation package that helps you judge how well you are using yourGERBERcutter.

data

Information stored on a disk.

default

A setting that is programmed into the computer at the factory. This is used until you override it byselecting another setting.

disk

A computer data storage medium made of plastic covered with a magnetic coating.

disk drive

A device that lets a computer read and write data on a 3.5 or a 5.25 inch disk.

downloading

Transmitting a file or program from a central computer to another computer (that is, from theoperator workstation PC to the MCC).

drill

An optional unit that attaches to the cutter head for making drill hole marks.

dry haul

The distance traveled with the knife out of the fabric.

dry run

Executing a cut file without plunging the knife or drill into the material.

emergency stop (ESTOP)

A red, push button that immediately stops all GERBERcutter motion.

Energy Saving Mode (ESM)

A vacuum feature that reduces vacuum to the cutting table when the cutter has been idle for acertain period of time.

front end processor (FEP)

Another name for the operator workstation PC.

hard disk drive

A computer data storage device that holds the software that runs the GERBERcutter. A hard diskdrive uses rigid metal disks to store large amounts of data.

Glossary Page 165

hardware

Physical elements of the computer, such as the monitor and keyboard.

heel cut

Cut made by the heel of the knife. The heel is the thickest edge (following edge) of the knife blade.

initialize

Setting the X0, Y0 coordinate for the cutting table after downloading the C200MT software. Thesystem uses this coordinate as a reference when processing a cut file.

keyboard

A device with keys, like those on a typewriter, that lets you enter data and communicate with theC200MT.

lateral drive

A table option. The cutting table can travel from one spreading table to another.

lay puller

A material handling system for Static systems.

left side

The left side of the table as seen from the take–on end.

limit switch

A switch that sets boundaries (limits) for cutter head or beam travel on the work surface of thecutting table. Limit switches also tell the C200MT when the cutter head reaches the X0, Y0coordinate when you initialize the system.

marker

Another name for a cut file being processed on the cutter.

monitor

A device like a television that receives computer video signals and displays information on thescreen.

motion control computer (MCC)

A computer that responds to instructions sent from the operator workstation PC to control cuttingtable motion.

network

A set of computers connected together.

network file server

A computer that provides a central database for other networked computers.

Glossary

operator workstation

The computer, monitor, and keyboard used to access the C200MT program and relay yourcommands, cut file data, and setup data to the Motion Control Computer (MCC) for processing.

origin

A point that represents the X0,Y0 location for the cutting table (or a marker). Every other point onthe table (or on the marker) is relative to the origin point.

parameter

A setting defined in a setup file.

plenum

A sectioned chamber that is part of the vacuum system.

printer

A device for putting computer data onto paper.

program

A set of instructions for a computer to execute. The programs that direct a computer are calledsoftware.

right side

The right side of the cutting table as seen from the take–on end.

Run Time Biting

A utility that bites the marker just before the GERBERcutter processes it.

servo motor

One of several electric motors used to move the beam along the X–axis, the cutter head along theY–axis of the cutting table, and control knife rotation on the C–axis.

setup

A computer data file that configures the system in a particular way, depending on what materialsyou are cutting.

software

Set of computer programs used to run the GERBERcutter and communicate with you. Theseinclude the C200MT program and Windows NT.

spread

One or more layers of material spread on a table for the purpose of cutting out pattern pieces.

static length biting

A method of biting in which each bite has the same length. In this method, some pieces are splitbetween bites.

Glossary Page 167

take–off end

The end of the cutting table where material leaves after being cut.

take–on end

The end of the cutting table that receives material for cutting.

utility

A program that helps you operate the computer. Examples include Queue Manager and FileManager.

vacuum gauge

Measures table vacuum. The vacuum pressure gauge in the Main Cutter Control screen displays thecurrent vacuum levels.

vacuum generator

The unit that makes a vacuum which is used to hold material firmly to the table work surface duringcutting.

vacuum level control

A vacuum feature that increases or reduces table vacuum depending on the current cutter mode(idle, bite, or cut).

variable length biting

A method of biting a marker so that pieces are not split between bites.

X–axis

A horizontal reference line in a coordinate system. The X–axis is the length of the table, from thetake–on end to the take–off end.

Y–axis

A vertical reference line in a coordinate system. The Y–axis is the width of the table, from the left(operator) side to the right (remote) side.

zoned vacuum

A vacuum feature that applies vacuum to a certain area of the cutting table. The cutting table isdivided into five more zones. Vacuum can be applied to one, two, or three zones at a timedepending on the pieces being cut. This feature is available only on Static and ZVC systems withpneumatic zoning.

Glossary

Appendix Page 169

$SSHQGL[$SSHQGL[

Knife and Drill Bit Part Lists

This appendix provides a list of knife blades and drill bits available from Gerberat the time this manual was printed.

Note: For the most current information, refer to the Service PartsCD–ROM. Ask your local Sales and Service office about theavailability of this useful tool.

Maintenance Checklists

For your convenience, checklists for 8, 40, 160, and 960 hour maintenanceschedules are included at the end of this appendix. See chapter 6 for detailedprocedures.

Note: To keep an electronic record of scheduled maintenance, use thechecklists available in the Training CBT feature. Ask your localSales and Service office about the availability of this CD–ROM.

Appendix

Knife Blades for S91 GERBERcutters

Various knife widths are available for your GERBERcutter. For example, 0.125knives are recommended for cutting heavy duty materials, such as denim whilecarbide knives are used for Aerospace applications. In addition to the knivesdescribed below, there is an optional knife setup for lingerie.

Note: Changing to a different knife width may require changing additionalparts in the knife drive train and the sharpener assembly. Check withyour Field Service representative.

KnifeWidth Description

GGT PartNumber

0.093 Knives 0.093 x 5/16 x 10 1/16, Hollow Ground, M2 Steel 021261008

0.093 x 5/16 x 10 1/16, Flat Ground, M2 Steel 021261009

0.093 x 5/16 x 10 1/16, Flat Ground, GKS 45 021261010

0.093 x 5/16 x 10 1/16, Hollow Ground 021261011

0.093 x 5/16 x 10 1/16, Flat Ground 021261012

0.093 x 5/16 x 10 1/16, Cryogenic Treated Knife 032426000

0.093 x 0.250 x 10 1/16, Flat Ground, M2 HS Steel, Silk Blade 078798003

0.093 x 0.250 x 10 1/16, Hollow Ground, M2 HS Steel, SilkBlade

078798004

0.093 x 0.250 x 10 1/16, Flat Ground, GKS 45, Silk Blade 078798005

0.078 Knives 0.078 x 0.200 x 10.00, Flat Ground, M2 HS Steel 022217005

0.078 x 0.200 x 10.00, Hollow Ground, M2 HS Steel 022217006

0.078 x 0.200 x 10.00, Flat Ground, GKS 45 022217007

0.125 Knives 0.385 x 0.125 x 10.00, Hollow Ground, M2 HS Steel 032419010

0.385 x 0.125 x 10.00, Flat Ground, M2 HS Steel 032419011


0.385 x 0.125 x 10.00, Hollow Ground, M2 HS Steel 039536003

0.385 x 0.125 x 10.00, Flat Ground, M2 HS Steel, Service Only 039536004


Carbide Knives 0.0625 x 0.188 x 2.00, Carbide Grade K68 034325000

0.0625 x 0.188 x 2.00, Carbide Grade Ramet #1 Ultra Fine 044274000

Appendix Page 171

Drill Bits, Ejectors, and Collets for S91 GERBERcutters

Note: Changing to a drill bit with a different diameter requires changing additionalparts in the drill assembly. Larger diameter drill bits also require an ejector.Check with your Field Service representative.

GGT Part Number

Description & Diameter Drill BushingEjectorRod

UpperCollet

LowerCollet

PresserFoot

solid 3/64 (0.047)(1.19 mm) 044330000 021706013 945500274

groove 5/64 (0.078)(1.98 mm) 030595003 021706007 945500274

(1/2) rnd 3/32 (0.093)(2.36 mm)

030595002 021706002 945500274

hollow 3/32 (0.093)(2.36 mm) 024351001 021706004 0243480015/64

945500274 945500274

(1/2) rnd 1/8 (0.125)(3.17 mm) 030595001 021706001 945500274

hollow 1/8 (0.125)(3.17 mm) 024351002 021706003 0243480027/64

945500274 945500274

hollow 5/32 (0.156)(3.96 mm) 024351003 021706005 0243480039/64

945500274 945500274

hollow 3/16 (0.187)(4.75 mm) 024351004 021706006 02434800411/64

945500274 945500274

hollow 0.197 (5 mm) 075782000 021706014 02434800411/64

945500274 945500274

hollow 1/4 (0.250)(6.35 mm) 072490000 021706008 02434800411/64

945500274 945500274

hollow 5/16 (0.313)(7.95 mm) 072490001 021706010 02434800411/64

945500274 945500274

hollow 3/8 (0.375)(9.53 mm) 031199004 021706011 02434800411/64

945500274 945500274

hollow1/2 (0.500)(12.7 mm) 031199003 021706009 060136000 945500274 945500274

hollow 19/32 (0.591)(15.01 mm)

031199005 060137000 060136000 945500274 945500274

hollow 21/32 (0.666)(17 mm) 031199007 064356001 060136002 945500274 945500274 021746001

hollow 3/4 (0.787)(20 mm) 031199006 064356000 060136001 945500274 945500274 021746001

Appendix

8 Hour Maintenance Schedule Checklist

See pages 79 through 83 for procedures. To keep an electronic record ofscheduled maintenance, use the checklists available in the Training CBT feature.

Initials/Date

• Check knife yaw alignment _____________

• Check knife offset alignment _____________

• Check Knife Intelligence alignment _____________

• Fill the tension arm oil cups _____________

• Fill the pivot arm oil cup _____________

• Clean and film coat the air cylinder rod for the elevator _____________

• Clean and film coat the elevator guide rods _____________

• Clean and lubricate the swivel assembly _____________

• Clean and lubricate the cutter tube _____________

• Clean and lubricate the knife articulating arm _____________

• Perform sharpener assembly maintenance _____________

• Clean and film coat the knife presser foot guide rods _____________

• Clean and film coat the air cylinder rod for the knife presser foot _____________

• Clean and film coat the drill(s) up/down air cylinder _____________

• Clean and film coat the air cylinder rods for the drill presser foot _____________

• Clean and film coat the Y–axis roundway _____________

• Clean and film coat the Y–axis squareway _____________

• Clean and film coat the X–axis roundways _____________

• Check the X–axis racks _____________

• Clean the vacuum intake filter _____________

• Check for fluid in air/reducer filters _____________

Appendix Page 173



Initials/Date

• Check the C–axis drive belt ______________

• Clean, lubricate, and check the C–axis servo gearing ______________

• Check tension of the knife drive belts ______________

• Check mechanical alignment of the knife ______________

• Check the head upper stop ______________

• Check the head lower stop ______________

• Check tension of the drill drive belt(s) ______________

• Clean, lubricate, and check the first X–axis pinion gearing ______________

• Clean, lubricate, and check the first X–axis servo gearing ______________

• Clean, lubricate, and check the Y–axis countershaft gearing ______________

• Clean, lubricate, and check the Y–axis servo gearing ______________

• Clean, lubricate, and check the second X–axis pinion gearing ______________

• Clean, lubricate, and check the second X–axis servo gearing ______________

• Check the torque tube drive belts ______________

• Clean, lubricate, and check the wheel housing cam rollers ______________

• Clean and lubricate the first X–axis wheel assembly ______________

• Clean and lubricate the second X–axis wheel assembly ______________

• Clean and inspect the bite encoder wheel ______________

• Perform X–axis spring scale test ______________

• Perform Y–axis spring scale test ______________

• Clean and film coat the clamp bar air cylinders (TCW) ______________

• Clean and film coat the resealer air cylinder rods (TCW) ______________

• Check resealer bar up/down air flow adjustment (TCW) ______________

Appendix



Initials/Date

• Check the knife speed adjustment (should be OK for one year) ______________

• Check the drill speed adjustment (should be OK for one year) ______________

• Check the Y–axis roundway bearings ______________

• Check the Y–axis squareway bearings ______________

• Check tension of the Y–axis belt ______________

• Check if the beam is square ______________

• Check the vacuum generator belts ______________

• Clean the vacuum stack filter ______________

• Check the conveyor drive alignment (TCW and ZVC) ______________

• Check the lay puller drive alignment (Static) ______________

Appendix Page 175



Initials/Date

• Check the knife motor bushings ______________

• Check the drill motor bushings ______________

• Lubricate the vacuum motor ______________

• Lubricate the Spencer vacuum turbine ______________

• Lubricate the Hoffman vacuum blower ______________

• Check alignment of the coupling for Hoffman blower ______________

• Check fluid level of the conveyor gear box (TCW and ZVC) ______________

Change every third time ______________

• Check fluid level of the lay puller gear box (Static) ______________


• Check fluid level of the surface cleaner gear box (TCW) ______________


• Lubricate the surface cleaner pillow block bearing (TCW) _____________

• Lubricate the platform drive cam roller bearings (TCW) ______________

• Clean and lubricate the platform drive chain (TCW) ______________

• Lubricate the platform drive sprocket bearings (TCW) ______________

• Check fluid level of the platform drive gear box (TCW) ______________


• Lubricate the platform drive shaft bearings (TCW) ______________

• Lubricate the platform wheel cam roller bearings (TCW) ______________

• Check the roller and clamps for overhead cable trolley (TCW) ______________

Appendix

Index Page 177

,QGH[,QGH[

AAir/Reducer Filter, 83, 135Alignment

coupling for vacuum assembly, 99, 137conveyor drive, 95, 139lay puller drive, 95, 140See also Knife Alignment

Applications, 159

BBCP, 13Beam, 4

maintenance, 82, 87, 92, 121square, 93, 129wheel assemblies, 125wheel housing cam rollers, 125See also X–axisSee also Y–axis

Beam Control Panel, 13cover, 122

Beam Square Test, 156Bearings

platform drive, 101roundway, 126squareway, 126surface cleaner pillow block, 132

BeltC–axis drive, 85, 113drill drive, 87, 118knife drive, 86, 114torque tube, 88, 123vacuum drive, 93, 136Y–axis drive, 93, 128

Bite, 23pause between, 43run time, 54static length, 54variable length, 54

Bite Encoder, 89, 125Blower

vacuum, 94, 98, 136

Bristle Locating Guides, 131

Bristle Penetration, 112BRISTLE SQUARES, 5, 130

rearranging, 131

CC Home to System Zero Diagnostic, 154C200 Controller, 3C200MT, 25

accessing, 30exiting, 41

CAM Applications, 160Categories

parameter, 52C–axis, 20

drive belt, 85, 113servo gear, 85, 113yaw alignment, 79

Check Origin, 43CIDB, 18, 60Circuit Breaker, 10

turn off, 41Clamp Bar, 89, 138

position first bite, 33Cleaner

solvents, 74work surface, 132

Colletpart numbers, 171

Config. See SetupConveyor

controls, 11drive alignment, 95, 139gear box, 99, 139position first bite, 33

Couplingalignment, 99, 137vacuum blower, 135

Covers, 103, 122, 135CTOT, 17Cut File, 25

opening, 36Cutter Head, 4, 103

See also HeadCutting

basic steps, 29

Index

speed, 39Cutview, 56

DData Preparation, 160Data Scale Factor, 44Diagnostics, 149

Beam Square Test, 156C Home to System Zero, 154Cut Tests, 155Heel to Heel Test, 157Input Output Test (DG 23), 151KI Calibration, 152Knife Offset Setup, 158

Drill, 17air cylinder rods, 81belt, 87, 118bit, 116, 171collet, 171drive belt, 118drive motor, 119ejector rod, 116, 171motor brushes, 97, 119part numbers, 171speed, 92, 119

EElevator, 112

air cylinder rod, 80guide rods, 80, 112head stops, 86, 112

End Capcover, 122

Ejector Rod, 116part numbers, 171

Error Messages, 144EStop, 9

plungers, 9switches, 8

Exiting, 41

FFabric Alignment, 42Feed Rate, 30

FEP, 15File Manager, 58Filters, 134

air/reducer, 83, 135stack, 83, 134vacuum, 82, 134

Flywheel Stroke, 86, 112

GGear

knife drive, 114X and Y–axis servo, 123X–axis pinon, 123Y–axis countershaft, 124

Gear Boxconveyor drive, 139lay puller, 140work surface cleaner, 132

HHead

cover, 103lower stop, 86, 112maintenance, 79, 85, 91, 97, 103upper stop, 86, 112

Heel to Heel Test, 86, 111, 157

IInitialize, 32Input Output Test (DG 23), 151

JJog

controls, 12position first bite, 33See also ConveyorSee also Lay Puller

KKI Calibration (DG 20), 152

Index Page 179

Knife, 106bristle penetration, 86, 112part numbers, 170reset for new, 65setting speeds, 66sharpen, 63, 162speed, 91, 115

Knife Alignmentmechanical offset, 86, 111, 156offset, 79, 158yaw, 79, 154

Knife Drivebelt, 86, 114motor brushes, 97, 115tension and pivot arms, 80, 113

Knife Drive Trainarticulating arm, 80, 105cutter tube, 80, 105swivel assembly, 80, 105

Knife Guides, 110Knife Presser Foot, 108

air cylinder rod, 81Knife Intelligence, 67

alignment, 79calibration, 152null, 67

Knife Motorturn on, 39

Knife Offset Setup, 157

LLaser Light

safety, xiv, 72turn on, 37

Lay Pullerdrive alignment, 95, 140gear box, 99, 140position first bite, 33tow bar, 33

Limit Switches, 7, 32Lubricants, 74

MMaintenance, 71

advanced X and Y–axis, 126basic X and Y–axis, 122beam, 82, 87, 92, 121C–axis, 85, 113cleaning, 74drill, 81, 87, 92, 97, 116electrical, 73elevator, 80, 86, 112filters, 82, 83, 94, 134head, 79, 85, 91, 97, 103knife, 106knife drive, 80, 86, 114knife drive train, 80, 104lubrication, 74material handling systems, 99, 138platform, 100, 141safety, 72roundway and squareway, 82, 92, 121roundways and racks, 82, 133sharpener assembly, 81, 107table, 82, 89, 93, 99tools, 75vacuum, 82, 93, 98, 135work surface, 130

Maintenance Schedule160 hour, 91, 17440 hour, 85, 1738 hour, 79, 172960 hour, 97, 175

Marker, 36Marker Report, 60Material Handling Systems, 138Motor

drill drive, 97, 119knife drive, 97, 115vacuum, 98, 136

OOperator Workstation PC, 15Origin, 21

check, 43

restore, 50set for cut file, 38

Overhead Cable Trolley, 102

Index

Overlay, 33

PParameter

categories, 52manager, 52

Partsnumbers for drill, 171numbers for knife, 170order, 74service CD, 159

Path Intelligence, 69Pause Between Bites, 43Piece Recut, 49Piece Search, 49Platform

controls, 11drive maintenance, 101, 141

Ply Heightconveyor drive alignment, 139lay puller drive alignment, 140maximum, 28

POWER Processor, 18Power Up, 30PreProcessor, 55Processing

cut file, 40Product Support, xi, 74, 143

QQueue Manager, 57

RRacks, 82, 133

plastic film caution, 33Recovery, 46

before, 46Bite Search, 50Piece Recut, 49Piece Search, 49

Restore Origin, 50Restore State, 47

Reports, 61Resealer, 89, 138

Restore State, 47manual, 48

Right Side Option, 17initialize, 32

Roundway, 82, 122bearings, 126

Roundways, 133Run Time Biting, 54

SS91

models available, 1Static, 2, 77TCW, 1, 76ZVC, 2, 77

Safety, xiii , 72Service Parts, 159Servo Power Enable, 31Setup, 25

change, 52selecting, 35

Sharpener Assembly, 81, 107knife presser foot, 81, 108

Shift Report, 61Shut Down, 41Software, 25Squareway, 82, 121Squaring the Beam, 129Stack

filter, 94, 134Spread, 28Spring Scale Test, 89, 127Static, 2, 77Support. See Product SupportSurface Cleaner

gear box, 100, 132pillow block bearings, 98, 132

Switches, 7EStop, 8knife, 30limit, 30

TTable, 130

maintenance, 82, 89, 93, 98, 130Take–off End, 19Take–on End, 19

Index Page 181

TCW, 1, 76Tool Codes, 56Tools, 75Torque Tube, 88, 123Training (CBT), 159Trim Cut, 45Troubleshooting

diagnostics, 149error messages, 144

Turbine. See VacuumTurn On, 30

UUnderlay, 28Utilities

C200MT, 51

VVacuum, 6

energy savings mode, 70hold down for application, 161readout, 11turn on, 37

Vacuum Maintenanceblower, 94, 136blower lubrication, 98coupling alignment, 99, 137coupling guard, 135belts, 93, 136filter, 82, 94, 134generator, 93, 136jack shaft cover, 135motor, 98, 136take–on cover, 135turbine, 98, 136

View Marker, 56

WWheel

assemblies, 88, 125housing cam rollers, 88, 125

platform drive, 101Windows NT, 25Work Surface, 5, 130Work Surface Cleaner, 132

gear box, 99, 132

XX–axis, 20

cam rollers, 88, 125pinion gear, 87, 123racks, 82, 133roundways, 82, 133servo gear, 87, 123spring scale test, 89, 127torque tube, 88, 123wheel assemblies, 88, 125

YY–axis, 20

bearings, 92, 126belt, 93, 128countershaft gear, 87, 124servo gear, 87, 123spring scale test, 89, 127

ZZVC, 2, 77

U.S.A./CANADA

Gerber Garment Technology, Inc.WORLD HEADQUARTERSP.O. Box 76924 Industrial Park Road WestTolland, Connecticut 06084 USATEL: (860) 871-8082FAX: (860) 871-6007

INTERNATIONAL

Gerber Garment Technology, Inc.INTERNATIONAL DIVISIONP.O. Box 76924 Industrial Park Road WestTolland, Connecticut 06084 USATEL: (860) 871-8082TLX: 192558 GGTIHQFAX: (860) 872-6742

EUROPE

GGT Europe N.V./S.A.Excelsiorlaan 55B-1930 Zaventem, BELGIUMTEL: (32) (2) 716 03 11FAX: (32) (2) 716 03 22

P/N 083878000Printed in USA 2/98

s91 Operator Manual

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