dcs 1500-2500 and taurus user guide

A-D-04212/2000

CUTTING EDGE DCS 1500/2500 MECHANICALand TAURUS TLCS GERBERcutter

USERS GUIDE

ii 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS

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Copyright 2000 by Gerber Technology, Inc., Cutting Edge division.

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Document Number A-D-04212/2000

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AccuMark, MicroMark, G (stylized logo) and Microdynamics are either registered trademarks, ortrademarks of Gerber Technology, Inc.

AutoCAD is a registered trademark of Autodesk, Inc.CADAM is a registered trademark of Dassault Systemes of America, Corp.CATIA is a registered trademark of Dassault Systemes, S.A.CorelDRAW is a trademark of Corel Corporation.Hewlett Packard is a registered trademark of the Hewlett Packard Company.In Focus and LP are trademarks or registered trademarks of In Focus, Inc.OptiTex is a registered trademark of Scanvec Garment Systems.PC is a registered trademark of International Business Machines Corporation.Pentium is a registered trademark of Intel Corporation.Trackball Pro is a trademark of CH Products.Virtek Leather Nesting software (AutoCut) is a registered trademark of Virtek Vision Corp.Windows 3.1, Windows 95 and Windows NT are registered trademarks of MicrosoftCorporation.

Table of Contents 12/2000 iii

TABLE OF CONTENTS

LIST OF FIGURES....................................................................................................................XI

LIST OF SCREENS ................................................................................................................XIII

LIST OF TABLES ....................................................................................................................XV

1.0 INTRODUCTION.............................................................................................................. 1-1

1.1 GENERAL .................................................................................................................... 1-3

1.2 SAFETY ....................................................................................................................... 1-31.2.1 PRECAUTIONS..................................................................................................... 1-31.2.2 SYMBOLS ............................................................................................................. 1-5

1.2.2.1 Control Panel.................................................................................................. 1-51.2.2.2 Keypad ........................................................................................................... 1-61.2.2.3 Labels............................................................................................................. 1-7

1.2.3 FORESEEN USES ................................................................................................ 1-81.2.4 NOISE EMISSIONS............................................................................................... 1-8

1.3 MANUAL DESCRIPTION ............................................................................................. 1-9

1.4 PARTS IDENTIFICATION .......................................................................................... 1-10

1.5 HOW TO CONTACT US ............................................................................................ 1-10

2.0 INSTALLATION ............................................................................................................... 2-1

2.1 GENERAL .................................................................................................................... 2-3

2.2 CUTTING SYSTEM SHIPPING WEIGHTS AND DIMENSIONS................................... 2-32.2.1 SHIPPING WEIGHTS AND DIMENSIONS DCS 1500........................................ 2-32.2.2 SHIPPING WEIGHTS AND DIMENSIONS DCS 2500........................................ 2-42.2.3 TAURUS TLCS SHIPPING WEIGHTS AND DIMENSIONS .................................. 2-4

2.3 MACHINE INSTALLATION REQUIREMENTS ............................................................. 2-52.3.1 TYPICAL CUTTING MACHINE INSTALLATION ................................................... 2-5

2.3.1.1 Cutting Machine Installation DCS 1500 ....................................................... 2-52.3.1.2 Cutting Machine Installation DCS 2500 ....................................................... 2-62.3.1.3 Cutting Machine Installation Taurus............................................................. 2-6

2.3.2 ENVIRONMENTAL TEMPERATURE AND HUMIDITY....................................... 2-72.3.3 AIR SUPPLY ......................................................................................................... 2-82.3.4 ELECTRICAL POWER.......................................................................................... 2-8

2.3.4.1 Electrical Requirements DCS 1500/2500..................................................... 2-82.3.4.2 Electrical Requirements Taurus................................................................... 2-82.3.4.3 Lightning Protection........................................................................................ 2-92.3.4.4 Machine/System Grounding ........................................................................... 2-9

2.4 INSTALLING THE CUTTING EDGE SOFTWARE ..................................................... 2-102.4.1 PC REQUIREMENTS DCS 1500/2500............................................................. 2-112.4.2 PC REQUIREMENTS TAURUS ....................................................................... 2-11

iv 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS

2.5 HARDWARE LOCK.................................................................................................... 2-122.5.1 INSTALL HARDWARE LOCK ............................................................................. 2-12

2.5.1.1 Configure the Hardware Lock ....................................................................... 2-122.5.1.2 Remove Modules from the Lock ................................................................... 2-13

2.5.2 SET PC MONITOR RESOLUTION DCS 1500/2500......................................... 2-142.5.3 SET PC MONITOR RESOLUTION TAURUS ................................................... 2-142.5.4 START CUTTING EDGE SOFTWARE................................................................ 2-14

2.6 CONFIGURE MACHINE............................................................................................. 2-15

2.7 CAMERA CONFIGURATION ..................................................................................... 2-21

2.8 CHECK MACHINE CALIBRATION ............................................................................. 2-22

3.0 DESCRIPTION................................................................................................................. 3-1

3.1 GENERAL .................................................................................................................... 3-3

3.2 MACHINE DESCRIPTION DCS 1500/2500............................................................... 3-3

3.3 MACHINE DESCRIPTION TAURUS TLCS ............................................................... 3-4

3.4 TABLE AND CARRIAGE .............................................................................................. 3-63.4.1 VACUUM TABLE................................................................................................... 3-63.4.2 SERVO MOTORS ................................................................................................. 3-63.4.3 LIMIT SWITCHES ................................................................................................. 3-63.4.4 BUMPER ARM SWITCHES................................................................................... 3-73.4.5 EMERGENCY STOP BUTTONS (E-STOPS) ........................................................ 3-73.4.6 HOMING SENSORS ............................................................................................. 3-73.4.7 TOOL HOLDER SENSORS................................................................................... 3-73.4.8 KEYPAD................................................................................................................ 3-83.4.9 PEN AND CUTTER PNEUMATICS ....................................................................... 3-8

3.5 CONTROL CABINET.................................................................................................... 3-93.5.1 SAFETY INTERLOCK SYSTEM............................................................................ 3-93.5.2 CONTROL PANEL ................................................................................................ 3-9

3.5.2.1 AC Power Switch............................................................................................ 3-93.5.2.2 Reset Button................................................................................................. 3-103.5.2.3 Status Board................................................................................................. 3-103.5.2.4 Pressure Gauges and Regulators ................................................................ 3-10

3.5.3 EXTERNAL INTERLOCKS.................................................................................. 3-10

3.6 PERSONAL COMPUTER (PC)................................................................................... 3-113.6.1 REQUIRED SOFTWARE MODULE .................................................................... 3-113.6.2 HARDWARE LOCK............................................................................................. 3-113.6.3 SERVO MOTION CONTROLLER ....................................................................... 3-11

Table of Contents 12/2000 v

3.7 OPTIONS ................................................................................................................... 3-123.7.1 SOFTWARE OPTIONS....................................................................................... 3-12

3.7.1.1 Toolpath Module........................................................................................... 3-123.7.1.2 Nesting Modules........................................................................................... 3-123.7.1.3 Extended AutoNest Yield Enhancement Module........................................... 3-123.7.1.4 Matching modules ........................................................................................ 3-123.7.1.5 CIM (Database) Module................................................................................ 3-133.7.1.6 CIM Administrator Module ............................................................................ 3-133.7.1.7 Rights and Access (R&A) Module................................................................. 3-133.7.1.8 Imaging Module............................................................................................ 3-13

3.7.2 HARDWARE OPTIONS ...................................................................................... 3-143.7.2.1 Laser Pointer ................................................................................................ 3-143.7.2.2 Spreader....................................................................................................... 3-143.7.2.3 Pneumatic Vacuum Shut Off System............................................................ 3-143.7.2.4 Pneumatic Reverse Air System .................................................................... 3-143.7.2.5 Pneumatic Dual Zone System ...................................................................... 3-14

4.0 OPERATING INSTRUCTIONS ........................................................................................ 4-1

4.1 GENERAL .................................................................................................................... 4-3

4.2 SAFETY ....................................................................................................................... 4-3

4.3 PRINCIPLES OF MACHINE OPERATION ................................................................... 4-44.3.1 CUTTING TOOL PRINCIPLES.............................................................................. 4-4

4.3.1.1 Wheel Cutter .................................................................................................. 4-44.3.1.2 Tangential Knife Cutter................................................................................... 4-44.3.1.3 Punch and Notcher Tools ............................................................................... 4-4

4.3.2 CUTTING PRESSURE.......................................................................................... 4-54.3.2.1 Wheel Cutter .................................................................................................. 4-54.3.2.2 Tangential Knife Cutter................................................................................... 4-5

4.3.3 INKING PRINCIPLES............................................................................................ 4-54.3.4 MATERIAL PROPERTIES..................................................................................... 4-6

4.3.4.1 Material Set .................................................................................................... 4-64.3.5 VACUUM TABLE OPERATION............................................................................. 4-74.3.6 PLASTIC OVERLAY.............................................................................................. 4-74.3.7 PAPER UNDERLAY .............................................................................................. 4-7

4.4 OPERATING CONTROLS............................................................................................ 4-84.4.1 KEYPAD OPERATION.......................................................................................... 4-8

4.4.1.1 Online Mode ................................................................................................... 4-94.4.1.2 Local Mode................................................................................................... 4-10

4.4.2 PC OPERATION ................................................................................................. 4-124.4.2.1 Basic Windows Concepts ............................................................................. 4-124.4.2.2 Basic Mouse Commands.............................................................................. 4-13

vi 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS

4.5 SETTING UP FOR NEW JOB .................................................................................... 4-144.5.1 CUTTING MACHINE CONTROL SETTINGS ...................................................... 4-14

4.5.1.1 Set Pen Pressure ......................................................................................... 4-144.5.1.2 Set Cutter Pressure ...................................................................................... 4-154.5.1.3 Adjust the Focus of the (Optional) Laser Pointer .......................................... 4-154.5.1.4 Removal and Installation of Wheel Cutter..................................................... 4-164.5.1.5 Setting Depth of the Tangential Knife ........................................................... 4-17

4.6 STARTING THE CUTTING MACHINE ....................................................................... 4-194.6.1 LOCAL MODE ERROR MESSAGE..................................................................... 4-20

4.7 SHUT DOWN THE CUTTING MACHINE ................................................................... 4-21

5.0 WORKING WITH JOBS................................................................................................... 5-1

5.1. GENERAL................................................................................................................. 5-3

5.2. OPENING A JOB FILE.............................................................................................. 5-35.2.1. OPENING A WORK ORDER................................................................................. 5-35.2.2. OPEN COMMAND................................................................................................. 5-4

5.2.2.1. Fast Open....................................................................................................... 5-5

5.3. JOB PARAMETERS.................................................................................................. 5-65.3.1. SETTING JOB PARAMETERS DIALOG BOX....................................................... 5-65.3.2. SPLIT TABLE OPERATION ................................................................................ 5-11

5.3.2.1. Job Origin in Split Table Mode...................................................................... 5-115.3.2.2. Mid-table Origins .......................................................................................... 5-12

5.3.3. NORMAL TABLE OPERATION DCS 1500/2500 .............................................. 5-135.3.3.1. Job Origin in Normal Mode ........................................................................... 5-13

5.4. PREPARE JOB....................................................................................................... 5-145.4.1. SET TOOLS AND TOOL PARAMETERS............................................................ 5-145.4.2. CHECK TOOL CONFIGURATION ...................................................................... 5-155.4.3. CONFIGURE SMART TEXT................................................................................ 5-15

5.4.3.1. Automatic Text ............................................................................................. 5-155.4.3.2. Operator Text ............................................................................................... 5-16

5.5. RUNNING THE JOB ............................................................................................... 5-175.5.1. START CUT JOB ................................................................................................ 5-175.5.2. USING OPTIONAL STOPS AND SMART STOPS .............................................. 5-195.5.3. STOP AND CONTINUE THE JOB....................................................................... 5-205.5.4. PARTS OUT OF BOUNDS.................................................................................. 5-20

5.6. MATCHING ON A DCS 2500.................................................................................. 5-215.6.1. SET MATCHING PARAMETERS ........................................................................ 5-215.6.2. MATCHING THE JOB ......................................................................................... 5-23

5.7. DIGITIZE PARTS.................................................................................................... 5-24

5.8. EXIT........................................................................................................................ 5-26

Table of Contents 12/2000 vii

6.0 CALIBRATION................................................................................................................. 6-1

6.1 GENERAL .................................................................................................................... 6-3

6.2 CALIBRATE MACHINE ................................................................................................ 6-36.2.1 BASIC CALIBRATION........................................................................................... 6-6

6.2.1.1 Square Carriage ............................................................................................. 6-66.2.1.2 Adjust Pneumatics.......................................................................................... 6-76.2.1.3 Set Scale Factor ............................................................................................. 6-96.2.1.4 Set Length.................................................................................................... 6-106.2.1.5 Set Stations .................................................................................................. 6-116.2.1.6 Check Y Belt................................................................................................. 6-126.2.1.7 Camera Calibration -- Taurus ....................................................................... 6-15

6.2.2 HOLDERS ........................................................................................................... 6-196.2.2.1 Align Cutter Angle......................................................................................... 6-196.2.2.2 Align Cutter Offsets ...................................................................................... 6-226.2.2.3 Align Punch Offsets...................................................................................... 6-256.2.2.4 Align Laser Pointer Offsets........................................................................... 6-266.2.2.5 Test Cut........................................................................................................ 6-27

6.2.3 TOOLS ................................................................................................................ 6-28

7.0 MAINTENANCE............................................................................................................... 7-1

7.1 GENERAL .................................................................................................................... 7-3

7.2 PREVENTIVE MAINTENANCE SCHEDULE ................................................................ 7-3

7.3 MACHINE MAINTENANCE PROCEDURES................................................................. 7-97.3.1 CLEAN AND LUBRICATE RAILS AND BEARING DCS 1500/2500.................... 7-97.3.2 CLEAN THE RAILS TAURUS............................................................................. 7-97.3.3 CLEAN AND LUBRICATE THE LINEAR BEARINGS TAURUS.......................... 7-97.3.4 CHECK FOR LOOSE RAIL JOINTS...................................................................... 7-97.3.5 INSPECT THE LINEAR BEARINGS FOR DAMAGE ........................................... 7-107.3.6 CLEAN THE RACK AND PINIONS...................................................................... 7-107.3.7 CHECK THE LIGHT BULBS TAURUS ............................................................. 7-107.3.8 CHECK THE CUTTING BLADE .......................................................................... 7-107.3.9 CHECK THE WHEEL CUTTER BOLT ................................................................ 7-107.3.10 CLEAN THE TABLE SURFACE TAURUS .................................................... 7-11

7.3.10.1 Create the Table Cleaning File ..................................................................... 7-127.3.10.2 Clean the Table Surface............................................................................... 7-15

7.3.11 CHECK THE EMERGENCY STOP BUTTONS................................................ 7-167.3.12 CHECK THE LOOP AND CHAIN FESTOONS................................................. 7-17

7.3.12.1 Check the X-axis Loop ................................................................................. 7-177.3.12.2 Check the Y-axis Chain Festoon .................................................................. 7-17

7.3.13 CHECK THE X-AXIS RACK AND PINIONS (ADJUST BACKLASH) ................ 7-207.3.14 CHECK THE RACK FOR DAMAGE OR ROUGH SPOTS ............................... 7-217.3.15 CHECK THE X-AXIS DRIVE HUB ................................................................... 7-21

viii 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS

7.3.16 INSPECT THE MOTORS................................................................................. 7-237.3.16.1 Inspect the X-axis motors ............................................................................. 7-237.3.16.2 Inspect the Y-axis motor............................................................................... 7-237.3.16.3 Inspect the Theta axis motor ........................................................................ 7-23

7.3.17 REPLACE THE WHEEL CUTTER BLADE BOLT ............................................ 7-247.3.18 CHECK AND LUBRICATE THE AIR CYLINDERS........................................... 7-257.3.19 REPAIR THE CUTTING SURFACE DCS 1500/2500.................................... 7-26

7.3.19.1 Repair a Wear-Damaged Table Surface DCS 1500/2500 ......................... 7-267.3.19.2 Repair Delamination or High Temperature Damage DCS 1500/2500........ 7-277.3.19.3 Repair to Raised Seams between Plastic Panels DCS1500/2500 ............. 7-29

7.3.20 REPAIR THE CUTTING SURFACE TAURUS .............................................. 7-307.3.20.1 Install Table Panels- Standard Hole Pattern ................................................. 7-307.3.20.2 Install Table Panels- High Density Table Surface......................................... 7-337.3.20.3 Remove the Table Surface Taurus ............................................................ 7-357.3.20.4 Replace One Table Surface Panel Taurus ................................................ 7-367.3.20.5 Repair Table Panel Glue Seam Taurus ..................................................... 7-37

7.3.21 CLEAN THE CONTROL CABINET FILTER..................................................... 7-387.3.22 LUBRICATE THE DRIVE BELTS..................................................................... 7-38

7.3.22.1 Lubricate the X-axis Belts ............................................................................. 7-387.3.22.2 Lubricate the Y-axis Belt............................................................................... 7-38

7.3.23 REPLACE THE X-AXIS DRIVE PINIONS ........................................................ 7-397.3.24 REPLACE AND/OR ADJUST THE X-AXIS LINEAR BEARING ....................... 7-417.3.25 CHECK THE THETA AXIS HEIGHT DCS 1500/2500 ................................... 7-447.3.26 CHECK THE THETA AXIS HEIGHT TAURUS.............................................. 7-457.3.27 REPLACE AND ADJUST THE DRIVE BELTS................................................. 7-46

7.3.27.1 Replace and Adjust the X-axis Belt DCS 1500/2500.................................. 7-477.3.27.2 Replace and Adjust the X-axis Belt Taurus................................................ 7-487.3.27.3 Replace and Adjust the Y-axis Belt DCS 1500/2500.................................. 7-497.3.27.4 Replace and Adjust the Y-axis Belt Taurus................................................ 7-517.3.27.5 Replace and Adjust the Theta Drive Belt ...................................................... 7-53

Table of Contents 12/2000 ix

8.0 TROUBLESHOOTING..................................................................................................... 8-1

8.1 GENERAL .................................................................................................................... 8-3

8.2 INTRODUCTION.......................................................................................................... 8-3

8.3 SOFTWARE CHECKS ................................................................................................. 8-48.3.1 CHECK DIRECTORY FOR CUTTING EDGE SOFTWARE................................... 8-48.3.2 CHECK FOR RECENTLY LOADED SOFTWARE................................................. 8-5

8.4 HARDWARE CHECKS................................................................................................. 8-6

8.5 CHECK BASIC MACHINE OPERATION ...................................................................... 8-6

8.6 SYSTEM DIAGNOSTICS ........................................................................................... 8-138.6.1 OFFLINE TESTS................................................................................................. 8-15

8.6.1.1 Joystick Signal Test...................................................................................... 8-158.6.1.2 Input / Output Test........................................................................................ 8-168.6.1.3 Encoder Test ................................................................................................ 8-178.6.1.4 Keypad Test ................................................................................................. 8-178.6.1.5 Servo Motion Controller Info ......................................................................... 8-188.6.1.6 Index Pulse Test........................................................................................... 8-18

8.6.2 ONLINE TESTS................................................................................................... 8-198.6.2.1 Homing Sequence Tests .............................................................................. 8-198.6.2.2 X/Y Festoon Test.......................................................................................... 8-208.6.2.3 Theta Torque and Run Out........................................................................... 8-218.6.2.4 Servo Torque Values.................................................................................... 8-22

9.0 VENDOR DOCUMENTATION ......................................................................................... 9-1

9.1 GENERAL .................................................................................................................... 9-3

9.2 NEMATRON INSTRUCTION MANUAL ........................................................................ 9-3

9.3 IMATRONIC APPLICATION NOTE .............................................................................. 9-3

10.0 GLOSSARY ............................................................................................................... 10-1

10.1 LIST OF TERMS ........................................................................................................ 10-3

x 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS

THIS PAGE INTENTIONALLY LEFT BLANK

List of Figures 12/2000 xi

LIST OF FIGURES

FIGURE 2-1 TYPICAL DCS 1500 INSTALLATION..................................................................................2-5FIGURE 2-2 TYPICAL DCS 2500 INSTALLATION..................................................................................2-6FIGURE 2-3 TYPICAL TAURUS INSTALLATION ...................................................................................2-6

FIGURE 3-1 TABLE LAYOUT ..................................................................................................................3-4FIGURE 3-2 KEYPAD, JOYSTICK, AND EMERGENCY STOP ..............................................................3-8FIGURE 3-3 CONTROL CABINET AND STATUS BOARD.....................................................................3-9

FIGURE 4-1 CROSS-SECTION OF AN OLFA BLADE............................................................................4-4FIGURE 4-2 PROPER AND EXCESSIVE BLADE PENETRATION. .......................................................4-5FIGURE 4-3 POSITION OF MATERIAL SET ..........................................................................................4-6FIGURE 4-4 KEYPAD ..............................................................................................................................4-8FIGURE 4-5 CUTTING EDGE SOFTWARE WINDOWS ICON ............................................................4-12FIGURE 4-6 CONTROL CABINET PANEL............................................................................................4-14

FIGURE 5-1 SPLIT TABLE OPERATION ..............................................................................................5-11FIGURE 5-2 MID-TABLE ORIGINS ON.................................................................................................5-12FIGURE 5-3 NORMAL TABLE OPERATION.........................................................................................5-13

FIGURE 6-1 WHEEL BLADE AND SHOULDER BOLT .........................................................................6-19FIGURE 6-2 POSITIVE X-AXIS CUTTER OFFSET ERROR ................................................................6-23FIGURE 6-3 POSITIVE Y-AXIS CUTTER OFFSET ERROR ................................................................6-23FIGURE 6-4 BLADE MISALIGNMENT CAUSING PROBLEMS WITH THE OFFSET TEST................6-24

FIGURE 7-1 CABLE AND HOSE CONFIGURATION DCS 1500/2500 ..............................................7-18FIGURE 7-2 CABLE AND HOSE CONFIGURATION TAURUS .........................................................7-19FIGURE 7-3 DRIVE HUB ASSEMBLY (DCS1500/2500) .......................................................................7-22FIGURE 7-4 MOTOR AND MOTOR BRUSH.........................................................................................7-23FIGURE 7-5 WHEEL CUTTER BOLT....................................................................................................7-24FIGURE 7-6 TABLE SURFACE .............................................................................................................7-31FIGURE 7-7 PLACEMENT OF STANDARD TABLE PANEL SURFACE...............................................7-32FIGURE 7-8 PLACEMENT OF HIGH DENSITY TABLE PANEL SURFACE.........................................7-34FIGURE 7-9 X-AXIS DRIVE HUB ASSEMBLY ......................................................................................7-40FIGURE 7-10 THETA AXIS ASSEMBLY HEIGHT...................................................................................7-44FIGURE 7-11 ADJUST X AXIS BELT TENSION ....................................................................................7-47FIGURE 7-12 THETA AXIS BELT ADJUSTMENT ..................................................................................7-53

xii 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS


List of Screens 12/2000 xiii

LIST OF SCREENS

SCREEN 2-1 HARDWARE LOCK CONFIGURATION DIALOG BOX..................................................2-14SCREEN 2-2 HARDWARE LOCK REMOVE MODULE DIALOG BOX ................................................2-15SCREEN 2-3 CONFIGURE MACHINE DIALOG BOX..........................................................................2-17SCREEN 2-4 TOOL OPERATIONS DIALOG BOX...............................................................................2-20SCREEN 2-5 ADVANCED CONFIGURATION DIALOG BOX..............................................................2-21SCREEN 2-6 CONFIGURE/CALIBRATE PASSWORD DIALOG BOX ................................................2-22SCREEN 2-7 PASSWORD VERIFICATION DIALOG BOX..................................................................2-22SCREEN 2-8 CONFIGURE CAMERA DIALOG BOX ...........................................................................2-23SCREEN 2-9 CALIBRATE MACHINE DIALOG BOX............................................................................2-24

SCREEN 4-1 SYSTEM STATUS DIALOG BOX ...................................................................................4-19SCREEN 4-2 HOME MACHINE DIALOG BOX.....................................................................................4-20SCREEN 4-3 LOCAL MODE ERROR MESSAGE ................................................................................4-20

SCREEN 5-1 SELECT WORK ORDER DIALOG BOX...........................................................................5-3SCREEN 5-2 OPEN DIALOG BOX .........................................................................................................5-4SCREEN 5-3 FAST OPEN DIALOG BOX...............................................................................................5-5SCREEN 5-4 JOB PARAMETERS DIALOG BOX ..................................................................................5-6SCREEN 5-5 GENERAL JOB PARAMETERS .......................................................................................5-8SCREEN 5-6 CUT-OFF PARAMETERS.................................................................................................5-9SCREEN 5-7 MAP LAYERS TO TOOLS ..............................................................................................5-14SCREEN 5-8 SMART TEXT DIALOG BOX FOR AUTOMATIC TEXT.................................................5-15SCREEN 5-9 SMART TEXT DIALOG BOX ..........................................................................................5-16SCREEN 5-10 CUT JOB AND START OPTIONS DIALOG BOXES ......................................................5-17SCREEN 5-11 PARTS OUT OF BOUNDS DIALOG BOX ......................................................................5-20SCREEN 5-12 MATCHING PARAMETERS DIALOG BOX DCS 2500................................................5-21SCREEN 5-13 DIGITIZE DIALOG BOX..................................................................................................5-24

SCREEN 6-1 CALIBRATE MACHINE DIALOG BOX..............................................................................6-3SCREEN 6-2 SQUARE CARRIAGE DIALOG BOX ................................................................................6-6SCREEN 6-3 ADJUST PNEUMATICS DIALOG BOX.............................................................................6-7SCREEN 6-4 SET Y SCALE FACTOR DIALOG BOX ............................................................................6-9SCREEN 6-5 SET LENGTH DIALOG BOX...........................................................................................6-10SCREEN 6-6 SET STATION DIALOG BOX .........................................................................................6-11SCREEN 6-7 CHECK Y BELT DIALOG BOX .......................................................................................6-12SCREEN 6-8 CAMERA CALIBRATION DIALOG BOX.........................................................................6-15SCREEN 6-9 ALIGN ANGLE TOOL HOLDER DIALOG BOX ..............................................................6-20SCREEN 6-10 ALIGN OFFSET TOOL HOLDER DIALOG BOX ............................................................6-22SCREEN 6-11 ALIGN OFFSET: PUNCH HOLDER DIALOG BOX ........................................................6-25SCREEN 6-12 LASER POINTER OFFSET CALIBRATION DIALOG BOX ............................................6-26SCREEN 6-13 TEST CUT DIALOG BOX ...............................................................................................6-27SCREEN 6-14 CALIBRATING TRAILER: NOTCHER DIALOG BOX .....................................................6-28

SCREEN 7-1 MACHINE TIMES DIALOG BOX.......................................................................................7-3SCREEN 7-2 DIGITIZE TABLE SURFACE DIALOG BOX ...................................................................7-12SCREEN 7-3 DIGITIZING A ROW OF VACUUM HOLES....................................................................7-14SCREEN 7-4 MAP LAYERS TO TOOL DIALOG BOX .........................................................................7-15

xiv 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS

SCREEN 8-1 FIND: ALL FILES DIALOG BOX ..........................................................................................8-4SCREEN 8-2 FIND: ALL FILES DIALOG BOX WITH LOCATED FILES...................................................8-5SCREEN 8-3 CUTTING EDGE ICON PROPERTIES................................................................................8-7SCREEN 8-4 DCS 2500 DIAGNOSTIC MENU.......................................................................................8-13SCREEN 8-5 JOYSTICK SIGNAL TEST DIALOG BOX .........................................................................8-15SCREEN 8-6 INPUT / OUTPUT DIALOG BOX ......................................................................................8-16SCREEN 8-7 ENCODER TESTS DIALOG BOX.....................................................................................8-17SCREEN 8-8 KEYPAD TEST..................................................................................................................8-17SCREEN 8-9 SERVO MOTION CONTROLLER INFO DIALOG BOX.....................................................8-18SCREEN 8-10 INDEX PULSE TEST DIALOG BOX ...............................................................................8-18SCREEN 8-11 HOMING SEQUENCE TESTS........................................................................................8-19SCREEN 8-12 X/Y FESTOON TEST DIALOG BOX...............................................................................8-20SCREEN 8-13 THETA TORQUE AND RUN OUT DIALOG BOX...........................................................8-21SCREEN 8-14 SERVO TORQUE VALUES DIALOG BOX.....................................................................8-22

List of Tables 12/2000 xv

LIST OF TABLES

TABLE 2-1 DCS 1500 SHIPPING CONTAINERS (5 TABLE) ..................................................................2-4TABLE 2-2 DCS 1500 SHIPPING CONTAINERS (6 TABLE) ..................................................................2-4TABLE 2-3 DCS 2500 SHIPPING CONTAINERS.....................................................................................2-5TABLE 2-4 NUMBER OF CONTAINERS FOR A DCS 2500 ....................................................................2-5TABLE 2-5 TAURUS TLCS SHIPPING CONTAINERS ............................................................................2-5TABLE 2-6 MINIMUM REQUIREMENTS FOR A DCS 1500 OR DCS 2500 MACHINE.........................2-13TABLE 2-7 MINIMUM REQUIREMENTS FOR A TAURUS MACHINE ..................................................2-13

TABLE 7-1 PREVENTATIVE MAINTENANCE SCHEDULE DCS 1500 AND DCS 2500.......................7-5TABLE 7-2 PREVENTATIVE MAINTENANCE SCHEDULE TAURUS...................................................7-7

xvi 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS


1SectionIntroduction

1-2 12/2000 DCS 1500/2500 Mechanical and Taurus TLCS


Section 1.0: Introduction 12/2000 1-3

1.1 GENERAL

This manual provides operation, maintenance and calibration instructions for the Cutting Edge DCS1500, DCS 2500 and Taurus TLCS (Total Leather Cutting Solution) GERBERcutters. Most of theinformation in this manual applies to all of these machines. However, some information in this manual ismachine-specific. The machine-specific information is noted with the machine type, with either DCS1500/2500 or Taurus TLCS in the heading.

For example, the minimum requirements for the PC used to run the Cutting Edge Software is divided intotwo sections: Paragraph 2.4.1 PC Requirements DCS 1500/2500 and Paragraph 2.4.2 PC Requirements Taurus. Paragraph 2.4.1 contains information specific to DCS 1500 and DCS 2500 machines;Paragraph 2.4.2 contains information specific to Taurus TLCS machines.

The Cutting Edge Division of Gerber Technology has followed stringent production methods to producea reliable and accurate machine that has been tested in our factory to verify its precision. Please read allof the following operating and service instructions so that you can realize the full potential of the cutterin daily plant operations.

1.2 SAFETY

In addition to the following safety precautions, this section provides a brief description of the varioussections that are included in this manual.

1.2.1 PRECAUTIONS

Instruct machine operators and observers to stand clear of the table while it is in operation. In somecases, it may be desirable to install a guardrail to prevent access to the table. For added security, you maywish to add a safety interlock to stop machine motion.

1. Only competent and qualified operators who have been properly trained by Gerber Technologyshould operate this machine.

2. Only competent and qualified service technicians who have been properly trained by GerberTechnology should service this machine.

3. Do not operate machine with safeguards or interlocks suspended.

4. Use only the cutting tools that are called out in the parts list in the Cutting Edge DCS 1500/2500GERBERcutter Engineering Drawings manual or the Cutting Edge Taurus TLCS GERBERcutterEngineering Drawings manual available from Gerber Technology, Cutting Edge Division.

5. Operating and maintenance people should read and understand the operating and serviceinstructions before working on the machine.

6. When servicing or maintaining the machine, all machine control panels must be tagged incompliance with OSHA Lock out/Tag out procedures to indicate that the machine should not beoperated.

7. Operators should not leave rolls of cloth or other material on the table surface in the path of thecarriage. Damage may occur if the carriage hits an object at full speed.


8. Do not attempt to move or interfere with fabric during cutting operation.

9. Never leave the machine unattended during cutting operation.

10. Turn electrical power off before opening any electrical enclosure.

11. Before performing any maintenance on the pneumatic system or parts moved by the pneumaticcylinders, disconnect the machine from the factory air supply.

12. Keep hands away from the carriage during machine operation or whenever the electrical powerand air are on.

13. Do not operate the machine with the cover of any enclosure or the guard or covers over anymechanism removed.

14. Push the red E-stop button on the carriage or control cabinet to halt the machine operation shouldany question of malfunction arise.

15. Before operating the machine at the beginning of each shift, all covers, guards and safety devicesshould be checked for proper operation.

16. Due consideration should be given to any safety regulation applicable to the particular plant inwhich the machine is operating.

17. Do not turn on machine power when cable(s) and/or printed circuit board(s) are disconnected.

18. The machine must not be used for any purpose other than for what it has been designed andapproved by Gerber Technology, Cutting Edge Division.

19. All electrical power switches including computer and vacuum blower power switches must belocated 2 to 6 feet (0.6 to 1.9 meters) from the floor.


1.2.2 SYMBOLS

Machine operators should be familiar with the following symbols on the control panel and keypad.

1.2.2.1 Control Panel

The following symbols are used on the status and control panels which are described in Section 3.0.Whenever these symbols are used in the manual, they will be shown as small caps with an initial largecapital letter, which indicates that the symbol is defined in this paragraph.

SYMBOL DESCRIPTIONEMERGENCYSTOP (E-STOP)

The red mushroom switches that are located at various locations on the machine.When pressed, all power is removed from the servo system and the machine stopsimmediately.

SYSTEMENERGIZED

The green light on the control panel indicating that the system has been energized.

RESET The Reset button on the control panel that applies power to the control cabinet.

AC POWER The AC power switch that sets power on to the control cabinet.

PEN The pen pressure indicator and regulator on the control panel.

TOOL HOLDER 1 The Tool Holder 1 pressure indicator and regulator on the control panel.

TOOL HOLDER 2 The Tool Holder 2 pressure indicator and regulator on the control panel.

CONTROL

POWER24 VDC READY

The electrical power indicator light on the control panel. When lit, it indicates thatthe electrical power switch on the control panel is set to On and 24 volt controlelectrical power is available to the components in the control cabinet.

SYSTEM ONLINE The status board indicator that is lit when the servo motors are energized.

RESET The status board button that energizes the servo system

MOTOR STATUS The lights on the control panel that indicate the status of the servo motor amplifiers.

XF-AXIS The status board light for the festoon side X-axis servo motor status.

XK-AXIS The status board light for the keypad side X-axis servo motor status.

Y-AXIS The status board light for the Y-axis servo motor status.

T-AXIS The status board light for the theta axis servo motor status.

E-STOP STATUSOPEN SWITCH

The status board light that indicates an open switch in the internal or externalinterlock switches.

HOMINGSENSOR STATUS

The status board lights for the homing sensors for the various servo axes.

X-HOME The status board light for the X-axis homing sensor status.

Y- HOME The status board light for the Y-axis homing sensor status.


1.2.2.2 Keypad

The following symbols appear on the keypad.

SYMBOL DESCRIPTIONF1 The keypad F1 button performs various functions depending on the machine

operational mode.

F2 The keypad F2 button performs various functions depending on the machineoperational mode.



!!!! The keypad Up arrow button (!!!!)performs various functions depending on themachine operational mode.

"""" The keypad Down arrow button("""")performs various functions depending on themachine operational mode.

+ The keypad Plus button (+) performs various functions depending on the machineoperational mode.

- The keypad Minus button (-) performs various functions depending on the machineoperational mode.

# The keypad CANCEL button (#) performs various functions depending on themachine operational mode.

The keypad RETURN button () performs various functions depending on themachine operational mode.


1.2.2.3 Labels

The following safety labels are used on the various parts of the machine. Refer to the Cutting Edge DCS1500/2500 GERBERcutter Engineering Drawings manual or the Cutting Edge Taurus TLCSGERBERcutter Engineering Drawings manual for illustrations that show the location of the followinglabels:

SYMBOL DESCRIPTION REFER TO FOR LABEL LOCATION PART NUMBER

DCS 1500/2500 TAURUS TLCS

Electricalgrounddirectly tomachineframe

Figure 2-4 and 2-5(Theta Axis)

Figure 2-26 and 2-24(Carriage)

CL-004-2(Control Cabinet)

Figure 2-12(Theta Axis)

Figures 2-17 and 2-18(Carriage)

CL-005-3CL-005-4(Control Cabinet)

L-100

Commonreferenceground

Figure 2-25(Carriage)


Figure 2-18Carriage Assembly


L-101

ElectricalInterference



CB2-120

Dangerelectricalshockpotential



CB2-124

Frictionhazard

Figures 2-24 and 2-25Carriage

Figure 2-16Carriage Beam

CB2-127

Movingmember

Figure 2-27(Carriage)

Figure 2-14(Carriage Assembly)

CB2-129

Pinch point Figure 2-9Carriage

Figure 2-11(Festoon Cover)

CR2-183


1.2.3 FORESEEN USES

The cutting machine is designed to cut single layer fabrics or leather. We have test cut materialssubmitted by your company prior to machine sale, and have provided you with test cut results, includingthe tool parameters that were used in the cutting process. Do not cut any material or operate the machinein any manner other than for the purpose that it was designed and sold without prior consultation withGerber Technology, Cutting Edge Division.

1.2.4 NOISE EMISSIONS

Gerber Technology, Cutting Edge Division has tested a cutting machine that is similar to the machinethat was delivered to you in an environment that is similar to a production environment. Actual noiselevels can vary depending on the location of the blower and machine. An industrial hygienist shouldperform a noise level study after installation to determine actual noise levels. The following noiseemissions have been measured during cutting machine operation with the vacuum blower located next tothe machine.

On a Cutting Edge DCS 1500/ 2500 GERBERcutter with a 3 horsepower blower installed next to themachine, the noise level is as follows:

With tool cutting, average A-weighted noise emission at control cabinet approximately 3 feet (1meters) from machine - 74 dB,

Maximum C-weighted noise emission at control cabinet approximately 3 feet (1 meter) from machine-90 dB.

On a Taurus TLCS GERBERcutter with a 10 horsepower blower located underneath the machine:

Average A-weighted noise emission in the work area around the cutter (3 feet or 1 meter) is 63 dB.


1.3 MANUAL DESCRIPTION

Section 2.0, Installation, includes general installation requirements, instructions for installing theCutting Edge Software and the hardware lock, and instructions for configuring the cutter.

Section 3.0, Description, includes a description of the table and carriage, control cabinet, personalcomputer, and available hardware and software options.

Section 4.0, Operating Instructions, includes a description of the principles of operation, a descriptionof machine operating controls, cutting machine control settings, and instructions for opening the CuttingEdge software.

Section 5.0, Working with Jobs, includes instructions for setting job parameters, opening a job file,preparing a job, and digitizing a new job. Specific instructions on how to use the other modules in theCutting Edge Software (Base Module, Toolpath Module, the Limited and Extended Nesting andAutoNest Modules, the CIM Module database, and the Rights and Access Module) can be found in theCutting Edge Software Users Guide.

Section 6.0, Calibration, includes instructions for calibrating the cutting machine, tool holders, andtools.

Section 7.0, Maintenance, includes a preventive maintenance schedule, and instructions for inspecting,lubricating, and maintaining the machine.

Section 8.0, Troubleshooting, provides troubleshooting and diagnostic procedures that are useful foridentifying and repairing machine malfunctions.

Section 9.0, Vendor Documentation, includes all vendor documentation such as parts lists andmaintenance instructions for vendor supplied equipment.

Section 10.0, Glossary, defines terms that are unique to the Cutting Edge Software, and to the cuttingsystems.


1.4 PARTS IDENTIFICATION

Most machine parts mentioned in this manual are shown in schematic or exploded diagrams in theCutting Edge DCS 1500/2500 GERBERcutter Engineering Drawings manual or the Cutting Edge TaurusTLCS GERBERcutter Engineering Drawings manual.

In North America, parts should be ordered from Gerber Technology, Service Department at 1-800-321-2448. Outside North America, call your local service office. If you have a service contract and areordering replacement parts under warranty, call 1-800-999-1448.

1.5 HOW TO CONTACT US

You can contact us by mail, telephone, fax, or electronic mail using the following information:

$ Mailing Address: Gerber Technology, Inc.Cutting Edge Division21 Lime StreetMarblehead, MA 01945

% Telephone number: 781-631-1390

% CEI Customer Service Number: 1-888-234-2887

Fax Number: 781-631-3983

& Electronic Mail: [email protected]

2InstallationSection

Section 2.0: Installation 12/2000 2-3

2.1 GENERAL

This section provides instructions for installing a Gerber Cutting Edge DCS 1500, DCS 2500, or TaurusTLCS GERBERcutters. This section includes general installation requirements, instructions for installingthe Cutting Edge Software and the hardware lock, and instructions for configuring the cutter.

A Cutting Edge DCS1500, DCS 2500 or Taurus TLCS cutter and any options must be installed orrelocated by Gerber Technology personnel only.

2.2 CUTTING SYSTEM SHIPPING WEIGHTS AND DIMENSIONS

The cutting machine is delivered in shipping containers. The following section describes the dimensionsand weights of the shipping containers for a standard DCS 1500, DCS2500 and Taurus TLCSGERBERcutter.

2.2.1 SHIPPING WEIGHTS AND DIMENSIONS DCS 1500

The DCS 1505 Sample Cutter table is 8 feet (2.4 meters) long by 70 inches (1.8 meters) wide and theDCS 1506 Sample Cutter table is 8 feet (2.4 meters) long by 82 inches (2.1 meters) wide. Althoughdisassembly is discouraged, by removing the table surface and tilting the base, the machine can fitthrough a doorway 30 inches (0.76 meters) wide if required.

The computer and control cabinet are shipped on a separate skid. The dimensions of the table andcarriage shipping boxes depend on the size of the table.

TABLE 2-1 DCS 1500 SHIPPING CONTAINERS (5 TABLE)

Item Inches Centimeters Pounds KgsComputer and Control Cabinet 22x70x 25 56x178x63 400 182Table (5 table) 74x101x40 188x256x 102 650 295Carriage (5 table) 88x24x30 224x61x76 325 148

TABLE 2-2 DCS 1500 SHIPPING CONTAINERS (6 TABLE)

Item Inches Centimeters Pounds KgsComputer and Control Cabinet 22x70x 25 56x178x63 400 182Table (6 table) 86x101x 40 218x 256x 102 700 318Carriage (6 table) 100x24x 30 254x61x76 350 159


2.2.2 SHIPPING WEIGHTS AND DIMENSIONS DCS 2500

The dimensions and weights in Table 2-3 are for a standard DCS 2500 machine. A fork lift truck or handdolly must be available to move the containers to the installation location.

TABLE 2-3 DCS 2500 SHIPPING CONTAINERS

Item Size L x W x H WeightInches Centimeters Pounds Kgs

Carriage Skid 100X24X30* 254X61X76 350 130.6Computer Skid 72X20X20 183X51X51 150 56Vacuum Blower Skid 40X40X40 102X102X102 350 130.6Panels/Legs Skid ** 80X50X30 203X127X76 400 149.3Extrusion/Beam Skid ** 144X20X20 366X51X51 200 74.65

* Carriage Skid may be longer if carriage is 120 inches (305cm) or wider.

** See Table 2-4 below for quantity of skids for longer machines.

TABLE 2-4 NUMBER OF CONTAINERS FOR A DCS 2500

Table Length Quantity ofPanels / Legs Skids

QuantityExtrusion -Beam Skids

12 Feet (3.66m) 1 124 Feet (7.31m) 2 2

36 or 48 Feet (11 or 14.63m) 2 360 Feet (18.3m) 2 4

72 Feet (22m) to 108 Feet (33m) 4 4

A work area of approximately 40 inches (one meter) is required on all sides of the machine for accessduring operation and maintenance.

2.2.3 TAURUS TLCS SHIPPING WEIGHTS AND DIMENSIONS

The dimensions and weights in Table 2-5 are for a standard Taurus TLCS machine. A fork lift truck orhand dolly must be available to move the containers to the installation location.

TABLE 2-5 TAURUS TLCS SHIPPING CONTAINERS

Item Size L x W x H Gross Weight Net WeightInches Centimeters Pounds Kgs Pounds Kgs

9' TABLE CRATE (1) 120 x 52 x 46 305 x 132 x 117 1450 658 1021 4639' TABLE CRATE (2) 120 x 52 x 46 305 x 132 x 117 1590 721 1161 5279' PANEL CRATE 120 x 52 x 46 305 x 132 x 117 2020 916 1591 72212' RAIL SKID 145 x 20 x 12 368 x 51 x 30 333 151 261 118COMPUTER SKID (1) 72 x 20 x 30 183 x 51 x 76 223 101 190 86COMPUTER SKID (2) 72 x 20 x 30 183 x 51 x 76 127 57 94 43BLOWER SKID 72 X 36 X 30 183 X 92 X 76 1020 462 850 385CARRIAGE CRATE 136 x 33 x 40 345 x 84 x 102 591 268 274 124

TOTAL 6334 2873 4592 2083


2.3 MACHINE INSTALLATION REQUIREMENTS

The following sections describe floor space, environmental, electrical, and air supply requirements forDCS 1500, DCS 2500 and Taurus TLCS GERBERcutters.

2.3.1 TYPICAL CUTTING MACHINE INSTALLATION

Refer to the preparation guide for area requirements for a particular application.

2.3.1.1 Cutting Machine Installation DCS 1500

Figure 2-1 is an example of a typical Cutting Edge DCS 1500 GERBERcutter installation.

FIGURE 2-1 TYPICAL DCS 1500 INSTALLATION


2.3.1.2 Cutting Machine Installation DCS 2500

Figure 2-2 is an example of a typical Cutting Edge DCS 2500 GERBERcutter installation.

FIGURE 2-2 TYPICAL DCS 2500 INSTALLATION

2.3.1.3 Cutting Machine Installation Taurus

Figure 2-3 is an example of a typical Cutting Edge Taurus TLCS GERBERcutters installation.

FIGURE 2-3 TYPICAL TAURUS INSTALLATION


2.3.2 ENVIRONMENTAL TEMPERATURE AND HUMIDITY

This machine must be operated in an environmentally controlled space to realize consistent accuracy andreliability. The temperature must always be between 55 and 80 degrees F (13 and 27 degrees C) and thehumidity must always be between 20 and 95 percent (non-condensing). The electrical equipment used onthe machine is capable of operating at altitudes up to 3500 feet (1067 meters).

Although the machine is designed to operate over a wide environmental range, prolonged operationbeyond extreme limits of temperature and humidity can have a substantial effect on the total reliability ofthe system. Environmental extremes will tend to shorten the useful life of both electrical and mechanicalcomponents and cause undesirable malfunctions. When Gerber Cutting Edge equipment is installed ingeographic areas where environmental conditions will be beyond the limits for prolonged periods oftime, it is recommended that the equipment be operated in a controlled environment. The effects of hightemperature will tend to reduce component life. High relative humidity will cause insulation pathbreakdown and promote fungus growth while low relative humidity, on the other hand, will promotestatic discharge which can alter the memory and degrade or destroy electronic components within thesystem.

For reliable operation, rapid changes in temperature should not occur during machine operation. Timeshould also be allowed for the equipment to stabilize at operating temperature after a non-operatingperiod during which the temperature had departed from the specified range.


2.3.3 AIR SUPPLY

Compressed air is used for several functions on the machine. The machine is delivered with a 1/4-inchfemale NPT fitting to mate to your supply line. The compressed air system must be able to supply 0.5SCFM (0.014 standard cubic meter/minute at 552 kPa) at 80 to 120 psi (552 - 828 kPa), and a filter/dryershould be installed somewhere between the compressor and the machine. The filter must remove 90-95percent of all particles 40 microns or larger.

2.3.4 ELECTRICAL POWER

The specific machine requirements are set in your Purchase Agreement and preparation guide. However,the machine is capable of operating with the voltage varying by up to +/-10 percent of the specifiedvalue. Also, the frequency can vary +/-1percent of the specified value.

NOTEFor European installations of DCS 1500/2500 and Taurus TLCS machines, allelectrical components must meet European Norm requirements.

On DCS 1500/2500 and Taurus TLCS machines, when the power switch is off, the carriage can bemoved by hand without damage. Once the power is on, the motors are energized and the machineoperator must not attempt to push the carriage by hand.

2.3.4.1 Electrical Requirements DCS 1500/2500

Wiring for the computer, control cabinet, and vacuum blower must conform to local electrical codes atthe point of installation and is the responsibility of the customer.

One dedicated grounded outlet is required at the location where you intend to install the computer andcontrol cabinet. The control cabinet should be plugged directly into the wall socket, not an UniversalPower Supply (UPS). The computers and monitors should be plugged into an appropriate UPS providedby you.

Generally, the computer and control cabinet are installed at the origin end of the cutting table.

Consult your Purchase Agreement and preparation guide for vacuum blower requirements, includingblower configuration, power ratings, circuit breaker and slow-blow fuse needs and system grounding.

2.3.4.2 Electrical Requirements Taurus

Wiring for the computer, control cabinet, and vacuum blowers must conform to local electrical codes atthe point of installation and is the responsibility of the customer.

Two dedicated grounded outlets are required at the location where you intend to install the computer andcontrol cabinet. The control cabinet should be plugged directly into the wall socket, not an UPS. Thecomputers and monitors should be plugged into an appropriate UPS provided by you.

Generally, the computer and control cabinet are installed at the mid-point of the cutting table.

Consult your Purchase Agreement and preparation guide for vacuum blower requirements, includingblower configuration, power ratings, circuit breaker and slow-blow fuse needs and system grounding.


2.3.4.3 Lightning Protection

The power lines should be equipped with lightning protection. Consult your local electrician for details.

2.3.4.4 Machine/System Grounding

Ground shall conform to local or national electrical code for the location of the installation. At the timeof machine/system installation, it is strongly recommended that adequate grounding be done by thecustomer; this is to keep electrical noise and differential potentials under control in large systems.

NOTEConsult local or national electrical code to determine the proper sizingand location of the electrical grounding connection.

All of these ground connections are in addition to (not in place of) the ground leads carried throughvarious signal cables and the ground conductors contained in the power cables. The ground wire in thepower cable must also be connected to the ground, usually through the conduit of the electricaldistribution system. This is a non-current carrying ground, not a neutral. The power cable conduit mustnot be used as the only ground connection. Whenever possible, the system's power panel should begrounded.

Whatever grounding system is used, it should provide less than 10 ohms impedance to moist earth fromDC to 10 MHz. The grounding system should also be isolated from electrical noise sources to preventelectrical noise being transmitted into the machine/system via the grounding system.


2.4 INSTALLING THE CUTTING EDGE SOFTWARE

The following paragraphs describe the minimum and the recommended requirements for a personalcomputer to run the Cutting Edge Software, and how to install the software using the Windows 95,Windows 98, or Windows NT 4.0 operating system. To install the software on a computer with WindowsNT 4.0, Log on to Windows NT as the System Administrator.

The software is supplied on a compact disk (CD). The installation program will prompt you as needed,and you should be able to install the Cutting Edge Software in a couple of minutes. When installing thenew software over an existing installation of Cutting Edge Software, none of the data, including job filesand machine operating parameters, in the existing software will be changed.

If the software is being installed for the first time, do the following:

Install hardware lock (see paragraph 2.5.1).

Set display driver (see paragraph 2.5.2 or 2.5.3).

Install the Cutting Edge Software (see below).

Start the Cutting Edge Software (see paragraph 2.5.4).

Check machine configuration (see paragraph 2.6).

Check machine calibration (see paragraph 2.8).

To install the software in Windows 95, Windows 98, or Windows NT 4.0, do as follows:

NOTE:Log on to Windows NT 4.0 as the System Administrator.

1. Place the Cutting Edge Software CD in the CD drive. The installation will begin automatically,unless the Autorun feature is disabled on the computer you are using.

If the software installation program does not start automatically, click the Start button on theWindows taskbar, and then click Run. The Run dialog box is displayed. Type D:\autorun.exe(where D:\ is the CD drive, otherwise substitute the appropriate drive letter) then click OK.

2. Click Install Software.

The Welcome screen appears.

3. Click the Next> button to begin the installation. Follow the instructions presented on the screen.

NOTE:If your system have the optional CIM Module, refer to

the Cutting Edge Software System Administration Guide for importantinstallation information before installing the software.


2.4.1 PC REQUIREMENTS DCS 1500/2500

Table 2-6 shows the minimum requirements, and Gerber Technologys recommendation for a personalcomputer running the Cutting Edge software:

TABLE 2-6 MINIMUM REQUIREMENTS FOR A DCS 1500 OR DCS 2500 MACHINE

MINIMUM REQUIREMENTS RECOMMENDED133 MHz Pentium 233 MHz Pentium

16 Megabytes (MB) RAM 32 MB RAM

28 MB free hard disk space 55 MB free hard disk space

Windows 95, 98 or NT 4.0 Operating System Windows 95, 98 or NT 4.0 Operating System

2.4.2 PC REQUIREMENTS TAURUS

Table 2-7 shows the minimum and recommended requirements for the personal computers used with theTaurus TLCS, or with personal computers running the Cutting Edge Software that will be used asNetwork Nesters or Strategy Nesters.

TABLE 2-7 MINIMUM REQUIREMENTS FOR A TAURUS MACHINE

MINIMUM REQUIREMENTS RECOMMENDED300 MHz Pentium 450 MHz Pentium

256 MB RAM 256 MB RAM

8 MB video card 8 MB video card

200 Megabytes (MB) free hard disk space 500 Megabytes (MB) free hard disk space

2 Gigabytes (G) free network space 5 Gigabytes (G) free network space

Windows 95, 98 or NT 4.0 Operating System Windows 95, 98 or NT 4.0 Operating System

NOTE:

The Cutting Edge software will not run on Windows 3.x operating system.


2.5 HARDWARE LOCK

A hardware lock, which is a small beige device, is included with the software and is needed for thesoftware on the personal computer to operate the machine. The hardware lock has password-protectedinformation that controls the features available to the user. Each working copy of the Cutting EdgeSoftware requires its own lock.

2.5.1 INSTALL HARDWARE LOCK

Install the hardware lock in the parallel printer port on the back of the personal computer. If a printer isalready plugged into the computer, remove the printer connector from the computer, install the lock onthe computer printer port, and then install the connector to the printer onto the lock.

2.5.1.1 Configure the Hardware Lock

Gerber Technology configures each customers hardware lock(s) with the modules purchased. If, in thefuture, a customer wishes to purchase an additional module, Gerber Technology will issue a password forthe new module along with instructions on how to install the module on their hardware lock.

You can view the features installed on your hardware lock by clicking the Help menu, then HardwareLock Configuration. The Hardware Lock Configuration dialog box (shown in Screen 2-1) will bedisplayed. This dialog box contains information, such as your hardware lock identification number, thatwill be helpful if you need to contact Gerber Technology Customer Service. Click OK to save anychanges made in the Hardware Lock Configuration dialog box. Click Cancel to exit this dialog boxwithout making changes.

SCREEN 2-1 HARDWARE LOCK CONFIGURATION DIALOG BOX


The fields in the Hardware Lock Configuration dialog box (shown in Screen 2-1) are as follows:

Lock ID The identification number for the hardware lock. You may need to refer to thisnumber when speaking with Gerber Technology Customer Service.

Lock Version This number identifies the version of the Cutting Edge Software that can run onthe lock. Lock Version 1 can run software version 2.21; Lock Version 2 can runsoftware version 3.0; Lock Version 3 can run software version 4.0. This numbercannot be changed.

Feature Lock This section describes the features available using the current lock.

Installed Features This list shows the Cutting Edge software modules that arecurrently installed on the hardware lock.

All Features This list shows all the modules available in the version of CuttingEdge software that is currently installed on the PC.

button to add the module to the hardware lock as a timed feature. Inthe dialog box that appears, type in the password issued by Gerber Technology,then click OK.

Features on Timer Displays features that are configured on the hardware lockfor a timed trial basis.

Time Remaining The time left for the trial mode.

Click OK to save any changes made in the Hardware Lock Configuration dialog box. Click Cancel toexit this dialog box without making changes.

2.5.1.2 Remove Modules from the Lock

When removing a module from the hardware lock, the software opens a dialog box that displays the LockID number, the Lock version, the name of the module you are removing, and the password used whenadding the module. You should keep a record of this information to use if you need to replace theremoved module.

To remove a module, select the module in the Installed Modules list, and click Remove. The dialog boxshown in Screen 2-2 is displayed. Click OK to remove the module from the software. The commandsassociated with that module cannot be used.

SCREEN 2-2 HARDWARE LOCK REMOVE MODULE DIALOG BOX


2.5.2 SET PC MONITOR RESOLUTION DCS 1500/2500

On a DCS 1500 or DCS 2500 cutter, the Cutting Edge Software runs most optimally when you set themonitor resolution to at least 800 X 600, and set the display color to High Color (16-bit).

To change the monitor display settings, follow the instructions in the User Guide for the PC operatingsystem.

2.5.3 SET PC MONITOR RESOLUTION TAURUS

On a Taurus TLCS cutter, the Cutting Edge Software runs most optimally when you set the monitorresolution to at least 1024 X 768, and set the display color to True Color (32-bit).

To change the monitor display settings, follow the instructions in the User Guide for the PC operatingsystem.

2.5.4 START CUTTING EDGE SOFTWARE

You can start an application by using the mouse to double-click (or choose) the program-item icon.

When you double-click (choose) the icon, the application appears in an application window. Sometimesyou may have several Windows open; the active Window is usually the one in the foreground. You maymake any Window the active Window by clicking anywhere in that Window.

Start the Cutting Edge Software as follows:

1. Set the power switch at the control cabinet to ON.

2. If not already on, turn on the personal computer.

3. Double-click the Cutting Edge software icon .


2.6 CONFIGURE MACHINE

The Configure Machine dialog box includes basic machine setup, tool holder, and tool configurationinformation. Click the Machine menu, then select the Setup command to display the Setup dialog box.Then click Cutter in the Configure group to display the Configure Machine dialog box shown inScreen 2-3. Make changes to the setup parameters as described below.

SCREEN 2-3 CONFIGURE MACHINE DIALOG BOX

Click OK to change the machine configuration after selecting the appropriate options. Click Cancel toexit this screen without changing the machine configuration.


General Configuration The general configuration parameters includes the following settings:

Machine Type The choices are either Mechanical Cutter, Laser Cutter,and Taurus Cutter. If you change the type of cutter, a dialog box appearswarning that you will lose the tool and tool holder calibrations if you acceptthe machine type change. Click Yes to change the machine type; click No tocancel without changing.

Com Port Select the Com Port used for communications to the keypad.Generally Com Port 1 is used, however, this depends on your installation.

Maximum Speed This is the maximum speed of the machine in units persecond. Use the Map Layers to Tools dialog box described in the CuttingEdge Software Users Guide to set the speed of the individual cutters.

Maximum Acceleration This is the maximum acceleration of the machinein units per second2.

Local Mode Speed This speed is used for the keypad local mode moves.

Y-Axis Travel (Inches) This sets the width of your table (Y-axis maximummovement). Select one of the available widths from the drop down list box ortype in a different value. If you select a size that is larger than your table, theY-axis assembly will hit the limit switch.

X-Axis Offset (Inches) This determines the location of machine originfrom the homing sensor position in the X-axis. All the available tools on theY-axis assembly can be used at this location and the default value of -7.25should not be changed unless instructed to by Gerber Technology.

Y-Axis Offset (Inches) Movement of the Y-axis assembly in the negativedirection from the homing sensor position. The default value of -3.875 shouldnot be changed unless instructed to by Gerber Technology.

Y-Axis Origin (Inches) Movement of Y-axis assembly in the positivedirection to machine origin from Y-Axis Offset. All the available tools on theY-axis assembly can be used at this location for machine origin. The sum ofthe Y-Axis Offset and Origin determine the location of the machine originfrom the homing sensor in the Y-axis. Machine origin must be located suchthat the pointer is located on the cutting surface. Machine origin determinesthe allowable travel for all tools in the Y-axis.

The default value of 1.125 should not be changed unless instructed to byGerber Technology. However, if the Y offsets for one of the tool holders isgreater than 1.125, the Y-Axis Origin will default to the Y offset for the toolholder. This may indicate an incorrect Y offset for the tool holder.

Stations A drop down list box allows the user to specify between 1 and 100stations to be used on the machine. After setting the number of stations,specify the position of each station using the Calibrate Machine dialog boxdescribed in Section 6.

Split Table Dead Zone The length in units of the dead zone in the middleof the table when using split table operation described in Section 5 of thismanual.


Holders Use the holder parameters to set the up and down delays for the various toolholders. Initially, default settings have been entered for the tool holders. Thesedefault settings can be modified as experience in machine operation is gained.Any increase in either the up or the down delay will slow machine operation andany decrease in delay will speed up machine operation. However, as youdecrease the up delay, you increase the chance that the tool may not be clear ofthe material before the Y-axis assembly moves. Conversely, as you decrease thedown delay, you increase the chance that the tool may not reach the materialbefore the tool starts its cutting move.

The pen has a default up and down delay of 0.150 seconds (150 milliseconds).Since the tool holders and the optional punch have sensors to detect when theyare retracted, their up delay should be set to 0. Set the down delay on these toolsto 0.010 seconds.

Holder - The name of the tool holder. This field cannot be changed through thesoftware.

Up Delay - On tool holders without position sensors, such as the pen and punch,the up delay is the time the machine waits after the signal is sent to raise the tooland the Y-axis assembly starts to move. On tool holders with position sensors,the up delay is the time the machine waits between the sensor off signal and theY-axis assembly starts to move.

Down Delay - On tool holders without position sensors, the down delay is thetime the machine waits after sending the tool down signal and the Y-axisassembly starts to move. On tool holders with position sensors, the down delay isthe time the machine waits between the sensor on signal and the Y-axis assemblystarts to move.


Tools Use the tool parameters to add or delete a tool and to set the tool trailer, tooloperations, and default holders for each tool.

Use the New command button to add a new tool and the Delete command buttonto remove a tool from the list. After clicking on New, a new Pen line isdisplayed in list (to change the name of the new tool, see Tool below). To deletea tool, click on the tool to highlight the tool and then click Delete.

Make appropriate changes to the New Tool line or any tool line by right-clickingthe entry. Type or select the changes in the text box and then press Enter.

Tool - Change the tool name by clicking the right mouse button on the name andtyping in the new name. The Edit Material Definitions dialog box described inthe Cutting Edge Software Users Guide displays the tools called out in this listbox.

Trailer - The trailer of the tool is the amount of caster that is assigned to thetool. On some cutters the blade trails behind the center of the holder for stability.The trailer is the distance from the center of the cut to the center of the holder.On wheel cutters the default trailer setting is 0.085 inch (2.16 cm) and on knifecutters the default trailer setting is 0.0.

Operations - This is the combination of operations that a particular tool canperform. Display the dialog box shown in Screen 2-4 by clicking the right mousebutton on the operations entry. Use the dialog box to select the type of operationsthat the selected tool can perform. When assigning tool operations, make certainthat the operations that are assigned to each tool are correct.For example, do not assign the knife to a drill operation or a punch to atangential operation.

SCREEN 2-4 TOOL OPERATIONS DIALOG BOX

Default Holder - The default tool holder defines the tool holder that is usedwhen assigning tools to holders in the Tool Mappings list box described in theCutting Edge Software Users Guide. As an example, if Tool Holder 1 is definedas the default holder for wheel cutter in the Configure Machine dialog box, theMap Layers to Tools dialog box defaults to Tool Holder 1 for the wheel cutter.


Advanced Use the Advanced configuration options to change the motion parameters andthe pointer tool. Click Advanced to display the Advanced Configuration dialogbox shown in Screen 2-5.

SCREEN 2-5 ADVANCED CONFIGURATION DIALOG BOX

Click OK to change the advanced configuration after selecting the appropriateoptions. Click Cancel to exit this screen without changing the advancedconfiguration.

Contouring This group controls the contouring of the machine when cutting apolyline. Contact Cutting Edge for additional information.

Pointer Sets the pointer that is used on the machine when the machine isjogged to a location. Use the pointer to identify a point or position on the cuttingtable. For example, when starting a job, the operator jogs the pointer to the joborigin and then starts the job. Also, when using op stops, the operator jogs thepointer to the op stop and then continues the job.

To select the Pointer, click the scroll button and then click either Pen Holder orLaser Pointer depending on machine configuration and operator preference.


Password Use the password to prevent unauthorized changes to the machine configurationand calibration settings. Click Password in the Configure Machine dialog boxto display the Configure/Calibrate Password dialog box shown in Screen 2-6.Use this dialog box to add, change, or delete the password used to access theConfigure and Calibrate Machine dialog boxes.

Type or delete the password and then click OK to add, change, or delete thepassword. Click Cancel to exit this screen without changing the passwordconfiguration.

SCREEN 2-6 CONFIGURE/CALIBRATE PASSWORD DIALOG BOX

If a password has been set up, the Password Verification dialog box displayswhenever the Configuration or Calibration dialog box is opened. Type thepassword and click OK.

SCREEN 2-7 PASSWORD VERIFICATION DIALOG BOX


2.7 CAMERA CONFIGURATION

The Configure Camera dialog box includes basic camera orientation, image resolution, and COM portinformation. Click the Machine menu, then select the Setup command to display the Setup dialog box.Then click Cutter in the Configure group to display the Configure Machine dialog box. Click theCamera button to display the dialog box shown in Screen 2-8Error! Reference source not found..Make changes to the setup parameters as described below.

SCREEN 2-8 CONFIGURE CAMERA DIALOG BOX

Camera Orientation Click the button that depicts how the camera is mounted on the cutter.

Vertical Mirror. This option properly orients the view from the cameraon the computer screen. This option is generally not selected for theDCS 1500, DCS 2500, or Taurus TLCS machine.

Corrected Image The camera image will initially appear to be bowed on the computerscreen. Adjust the pixel size to flatten the image. Type a value in thePixel Size text box. The smaller the size typed in, the closer the imagewill be to the original.

COM Port Specify the port used for the camera.

Calibration Grid The cutter uses the information in this group to help calibrate thecamera. The pen on the cutter draws a grid that is used during the cameracalibration.

Horizontal Targets (Left/Right in Camera Image). Type the numberof vertical lines to include in the calibration grid.

Vertical Targets (Up/Down in Camera Image).Type the number ofhorizontal lines to include in the calibration grid.

Target Spacing. Type the distance between the lines in each direction.


2.8

dcs 1500-2500 and taurus user guide

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