Gerber GS15 Plus User Manual
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Gerber GS15 Plus User Manual

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USER'S MANUAL

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Summary of Contents for Gerber GS15 Plus

  • Page 1     plus GS15 USER'S MANUAL...
  • Page 3 Gerber Scientific Products, Inc. GRAPHIX ADVANTAGE is a registered trademark of Gerber Scientific Products, Inc. 3-in-1 is a registered trademark of Boyle-Midway, Inc. HP-GL is a registered trademark of Hewlett Packard. 3M, ScotchCal, and Scotchlite are trademarks of 3M.
  • Page 5 FCC NOTICE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ......................1 Description ....................1 Performance....................1 Convenience ..................... 2 Support Information ................. 2 PACKAGE CONTENTS ....................5 INSTALLATION ....................... 7 Plotter Work Area ..................7 Connect to the Plotter................8 Communication Parameters..............8 Power Cords ..................... 9 Power-Up Sequence ................
  • Page 8 Pounce Wheel Replacement ............26 Knife Holder and Blades ................ 27 Blade Wear ..................27 Blade Damage.................. 27 Knife Holder Installation ..............28 Blade Replacement ................30 OPERATION........................33 Power-Up....................33 Front Panel ..................... 34 SLEW Keys ..................35 SLOW Key..................35 SWIVEL KNIFE................
  • Page 9 Objective..................61 Adjustment Procedure..............61 X Axis Belt Adjustment ................. 66 Symptoms..................66 Objective..................66 Adjustment Procedure..............66 Y Axis Backlash Adjustment ..............69 Symptoms..................69 Objective..................69 Adjustment Procedure..............69 Drum End Play Adjustment..............73 Symptoms..................73 Objective..................73 Adjustment Procedure..............

  • Page 11: Introduction

    Swivel Knife Mode is used for rapid cutting of all but the most demanding materials such as sandblast stencil. Gerber's exclusive Corner Correcting Technology™ assures sharp, easy-to-weed corners in swivel knife mode.

  • Page 12: Convenience

    Convenience plus GS15 has many features that make it easy and convenient to use: Accepts any standard Gerber materials in 15-inch (38.1 cm) wide rolls. Draws, cuts and pounces up to 12.75 inches (32.4 cm) high. Using plus the GRAPHIX ADVANTAGE system Panel feature, the GS15 can cut text or graphics in strips up to 96 feet (29.3 meters) long and...

  • Page 13: About This Manual

    Introduction About This Manual plus This manual explains the installation and operation of the GS15 plotter. It tells you how to assemble, install, operate, and maintain your plus GS15 as follows: plus The "Introduction" provides information about the GS15 and a list of contents of the shipping crates.
  • Page 14 plus 4 GS15 Conventions The following conventions are used in this manual: Note: A note contains important information which could affect successful completion of a task. CAUTION: A caution statement contains information which, if not observed, could result in damage to the equipment. WARNING: A warning statement contains information which, if not observed, could result in personal injury.

  • Page 15: Package Contents

    PACKAGE CONTENTS plus This section lists the contents of the GS15 shipping container. As plus you unpack the GS15 plotter, inspect all items for damage that may have occurred during shipping. Report any damage to your dealer at once. Save all packaging materials in case it becomes necessary to transport the plotter at a future date.
  • Page 16 plus 6 GS15 Contents: Tool Kit Pen holder with pen Tangential knife holder with blade Pounce wheel holder Tool lift washers (on tool holders) Allen wrench Pair tweezers Spare red pen Spare blue pen Envelope containing 2 spare lift washers Spare cone-shaped tool caps Capsule containing: Spare knife blades...

  • Page 17: Installation

    Note: Should you experience difficulty during installation of the plus GS15 to the GRAPHIX ADVANTAGE system, contact Gerber Field Service Department at 800-828-5406. Plotter Work Area plus 1. Carefully remove the GS15 from its packaging materials and place it near the GRAPHIX ADVANTAGE system.

  • Page 18: Connect To The Plotter

    plus 8 GS15 Connect to the Plotter CAUTION: Be sure power is turned off and the power cord is unplugged at both the GRAPHIX ADVANTAGE and the plotter. 1. Insert the 9-pin connector at the end of the RS-232 cable into the 9- pin RS-232 connector on the back of the GRAPHIX ADVANTAGE.

  • Page 19: Power Cords

    Installation The plotter has a 25DB female connector with these pin assignments: Signal Sig Gnd All other pins are not connected. Power Cords plus 1. Insert the female connector of the GS15 plotter power cord into the socket on the rear panel of the plotter. 2.

  • Page 20: Power-Up Sequence

    plus 10 GS15 CAUTION: When the power is on, never try to manually move the carriage, move the drum, rotate the tool, or force the tool up plus or down. Attempting to manually move the GS15 in any axis of movement while the power is on may damage the plotter. Power-Up Sequence plus When the GS15...

  • Page 21: Setup

    SETUP After connecting the plotter to the GRAPHIX ADVANTAGE, you will use the GSP Setup program in GRAPHIX ADVANTAGE to make the plus GS15 accessible. plus Note: When the GS15 is used with sign design systems other than GRAPHIX ADVANTAGE, contact the system manufacturer to obtain a plus driver for the GS15 and for setup information.

  • Page 22: Add Plotters

    plus 12 GS15 Note: The Default Plotter note in the lower right corner of the dialog box tells you the name of the plotter your jobs will be sent to unless otherwise specified in the Plot program. 7. Click on Continue. The screen will return to the GSP Setup Menu. 8.

  • Page 23: Assign Default Plotter

    Setup Assign Default Plotter A default plotter can be assigned if more than one plotter is connected to the GRAPHIX ADVANTAGE. Note: There must be two or more plotter names in the Ready for Plotting box to select a default plotter. If only one plotter is installed to the GRAPHIX ADVANTAGE system, that plotter will automatically be assigned as the default plotter.

  • Page 25: Materials And Tools

    The GS15 uses the same plotting materials as all Gerber plotters. Gerber vinyl products in high performance or intermediate grades are available in translucent, reflective, or metallic finishes and come in a wide range of colors. Also available are direct-cut screenprint stencil, ruby photo film, paint masking material, rubber sandblast stencil material and heat transfer materials.
  • Page 26 plus 16 GS15 2. Center the carriage spindle preferably by using the slew keys (see "Front Panel" section) or manually, with certain precautions as outlined here. Be sure that the carriage spindle is not located at either extreme end of its travel and that both ends of the rubber drum can be reached easily.
  • Page 27 Materials and Tools To feed and align material 1. Feed material under the black cam shaft and over the rubber drum. See the illustration below. 2. Place the holes in the material over the sliding sprocket pins first. Match the three closely spaced sprocket pins and holes. 3.

  • Page 28: Helpful Hints

    plus 18 GS15 HELPFUL HINTS When you change materials, open the bail arms and roll the material back onto the roll. Tape the ends securely to prevent the roll from unraveling. Before unrolling vinyl for a job, determine how much material you need.

  • Page 29: Tool Force Dial

    Materials and Tools Tool Force Dial The tool force dial on the front of the housing indicates the tool force setting and the amount of tool force, or pressure, that is applied to the tool during operation. This pressure ensures uniform cuts and pen lines. Tool force can be adjusted by turning the small knob on the end of the tool force housing, as shown in the illustration below.

  • Page 30: Adjustments

    Blade wear — Increase tool force after several thousand cuts. Gerber recommends experimenting with tool force settings as well as keeping a logbook of the settings. Refer to the Plotter User Reference...

  • Page 31: Tools And Tool Handling

    TOOLS AND TOOL HANDLING Storage plus A tool rack is molded into the rear cover of the GS15 . The pen holder, knife holder and pounce wheel holder may be removed from the tool kit and stored here for easy access. Tool Holders For quick identification, each tool holder has a different colored cap.

  • Page 32: Pen Holder And Pens

    plus 22 GS15 Pen Holder and Pens The pen holder is shipped with a black pen installed. After loading the plotting paper, install the pen holder in the carriage spindle as follows: To install the pen holder 1. Select the pen holder with pen installed from the tool rack molded in the rear cover.

  • Page 33: Pen Replacement

    PEN REPLACEMENT Spare pens in blue and red are included in the tool kit. Additional pens are available through a Gerber distributor. To replace a pen 1. Insert a flat-tip screwdriver into the notch at the base of the cone- shaped cap (see below).
  • Page 34 plus 24 GS15 5. Push down on the upper end of the pen until the point just touches the table surface. 6. Use the Allen wrench to tighten the set screw near the tip of the pen. Do not over-tighten the set screw or the pen could be crushed. 7.

  • Page 35: Pounce Wheel Holder

    Tools and Tool Handling Pounce Wheel Holder Pouncing is a technique used to create an outline for a sign that will later be hand-painted. Pouncing can also be used to align vinyl letters on a large job. The pounce wheel is designed to pounce (perforate) holes either perfectly aligned or off-center to the direction of travel.

  • Page 36: Pounce Wheel Replacement

    plus 26 GS15 2. A plastic lift washer is used to reduce friction between the tool and the lift fork of the carriage spindle during operation. There should be one installed on the pounce wheel holder. If not, slip a lift washer from the tool kit over the barrel and slide the washer to the top of the holder.

  • Page 37: Knife Holder And Blades

    Tools and Tool Handling Knife Holder and Blades Gerber blades are extremely wear-resistant. In testing, over 10,000 one- inch letters were cut using a single blade before testing was discontinued with the blade still cutting satisfactorily. Other blade manufacturers have attempted, unsuccessfully, to duplicate this cutting precision and plus durability.

  • Page 38: Knife Holder Installation

    plus 28 GS15 KNIFE HOLDER INSTALLATION plus The GS15 comes with two different types of knife holder: Swivel Knife - Used to cut all but the thickest materials, such as sandblast stencil, at high speed. Tangential Knife - Used to cut all materials, including sandblast stencil.
  • Page 39 Delux 210 Gold/Silver Dusted Crystal 210 .05-1 GS 35 Florescent 210 Scotchcal™ 220 Translucent 230 Gerber Cal® Gerber IP Plus GerberMask™ I & II GS 35 Heat Transfer Flock Hot Split Plastisol Metalized Polyester Screen Print GS 35 Static Cling...

  • Page 40: Blade Replacement

    Extra blades and special angled blades for sandblast vinyls are available from your Gerber distributor. WARNING: The blade is very sharp. Take care when handling the knife holder and blade.
  • Page 41 Tools and Tool Handling To replace and adjust the swivel knife blade 1. Remove the plastic adjustment shoe from the base of the tool holder by rotating it counter- clockwise until it comes completely off the tool holder. Leave the rubber O ring in place. Rubber O ring With the shoe removed, carefully 2.

  • Page 43: Operation

    OPERATION Power-Up plus When the GS15 is turned on, the following sequence occurs: 1. A short beep sounds, the Power light comes on, and the RUN CONT, RUN SING, and SWIVEL KNIFE lights blink. plus 2. As the GS15 performs self-check tests, the lights over the RUN and SWIVEL KNIFE keys flash, and one additional beep sounds.

  • Page 44: Front Panel

    plus 34 GS15 Front Panel plus The GS15 front panel keys shown below are used to perform all of the following operations: Position the carriage and material. Put the plotter on-line for drawing, cutting, and pouncing. Select single or continuous job processing. Select knife mode.

  • Page 45: Slew Keys

    SLOW of artwork produced by the GERBER EDGE . In normal or slow mode, the platen or tool move continuously as long as the arrow keys are pressed.

  • Page 46: Swivel Knife

    plus 36 GS15 SWIVEL KNIFE Press the SWIVEL KNIFE key to select knife mode: SWIVEL When the swivel knife mode is selected, the light over the SWIVEL KNIFE KNIFE key is on. If the tangential knife mode is desired, the light must be off. Press SWIVEL KNIFE to turn the light on and off.

  • Page 47: Run Single

    Operation RUN SINGLE Plot Use RUN SINGLE to plot a single job. This plot mode allows the operator to reposition material between jobs and/or to pen plot using SINGLE paper before cutting vinyl. RUN SINGLE may be used with either swivel knife mode or tangential knife mode.

  • Page 48: Run Cont

    plus 38 GS15 Single Plot Exercise plus 1. Turn on the GS15 . Load plotting paper, test the pen manually, install the pen holder, and set the tool force to .5. 2. Using the slew keys, position the carriage spindle approximately 1" from the front edge of the plotting paper.
  • Page 49 Operation Controlled Stop Use RUN CONT (or RUN SINGLE) to pause plotting and check the current job. To stop a continuous mode plot plus 1. Press either RUN key. The GS15 stops the plot at the next logical break in the program. Do not use slew keys or orientation for the current job will be lost.

  • Page 50: Reset

    plus 40 GS15 RESET Use the RESET key to stop plotter operation in case of emergency, to clear error signals, and to access Special Diagnostics. RESET To cause an emergency stop Press the RESET key while a job is plotting. The following sequence occurs: plus 1.

  • Page 51: Special Diagnostics

    SPECIAL DIAGNOSTICS In addition to the self-check tests that are part of the power-up sequence, plus the GS15 plotter can perform other special diagnostics. The steps to access these diagnostics and their functions are outlined below. To access special diagnostics 1.

  • Page 52: Diagnostic Options

    Y, Z, theta axes in cut mode and to verify operation after adjustments are made. X08 Cut Test - Press the down arrow key to access. Use to test cut quality. If the plotter consistently fails a special diagnostic, contact Gerber Field Service Department at 800-828-5406, or fax at 203-645-2448.

  • Page 53: Wagon Wheel Test Plot

    2. Load plotting paper and install the pen holder. 3. Press left arrow key to access diagnostic. 4. Press RUN SINGLE to plot once or RUN CONT to plot continuously. 5. Compare the test plot to the illustration below. If the plot is different, contact Gerber Field Service.

  • Page 54: Square/Circle Test Plot

    2. Load vinyl and install the knife holder. 3. Press SLOW key to access diagnostic. 4. Press RUN SINGLE to plot once or RUN CONT to plot continuously. 5. Compare the test plot to the illustration below. If the plot is different, contact Gerber Field Service.

  • Page 55: X08 Cut Test

    2. Load vinyl and install the knife holder. 3. Press the down arrow. 4. Press RUN SINGLE to plot once or RUN CONT to plot continuously. 5. Compare the test plot to the illustration below. If the plot is different, contact Gerber Field Service.

  • Page 57: Error Conditions

    ERROR CONDITIONS plus The GS15 is programmed to detect several mechanical/electrical error conditions at power-up or during operation. When an error condition occurs, the plotter will turn off power to the stepper motors, flash the RUN lights, and sound a steady tone. To determine the error condition that stopped plotter operation, follow these steps.

  • Page 58: Error Codes

    Turn off system; check connectors *Error code occurs in Special Diagnostic mode, if axes remain locked more than 30 minutes. If the plotter consistently fails the self-check tests, contact Gerber Field Service Department at 800- 828-5406, or fax at 203-645-2448.

  • Page 59: Service And Maintenance

    SERVICE AND MAINTENANCE This section includes instructions for routine cleaning and lubrication, plus fuse replacement, and adjustments to keep the GS15 plotter in good working order. Cleaning and Lubrication Routine cleaning and lubrication should be done monthly or after every 160 hours of use, whichever occurs first.

  • Page 60: Carriage And Ball Bushing

    plus 50 GS15 CARRIAGE AND BALL BUSHING 1. Use a lint-free cloth and alcohol to clean any dust or debris from the front way, drive shaft, cam shaft and rear way. Rotate the cam shaft and rear way (the front way does not turn) and move the carriage spindle for access to the entire length of these shafts.
  • Page 61 Service and Maintenance 3. Tip the plotter on its left side. CAUTION: Do not rest the plotter on its right side. Do not use the way shaft to lift or turn the plotter. 4. Place one or two drops of oil on each side of the ball bushing (as indicated) and in the oil hole.

  • Page 62: Sprockets And Bail Arms

    plus 52 GS15 SPROCKETS AND BAIL ARMS 1. Inspect the teeth of the drum sprockets for adhesive buildup from the use of vinyl films. 2. Use a small stiff brush (such as a toothbrush) dipped in alcohol to clean the sprockets. 3.

  • Page 63: Fuse Replacement

    Service and Maintenance Fuse Replacement plus Two spare fuses are included with the GS15 plotter. The fuse holder is located between the on/off switch and the power cord connector on the rear panel of the plotter. To replace the fuse WARNING: turn off power at the plotter and the system and disconnect from the power supply.
  • Page 64 plus 54 GS15 5. Pull out the light gray fuse carriers one at a time. Note that each carrier has a white arrow on it and that the arrow points downward (as do the two arrows on the black plastic plate). 6.

  • Page 65: Plotter Adjustments

    It also contains a brief description of plotter adjustment problems that should be handled by contacting Gerber Field Service Department at 800-828-5406. Note: Gerber warranties do not cover unauthorized repair. Some service procedures require delicate adjustment of plotter parts.

  • Page 66: Troubleshooting Guide

    plus 56 GS15 Troubleshooting Guide This chart of Z Axis (Tool Height) Adjustment symptoms is designed to help identify the possible problem and the probable adjustment procedure. plus CAUTION: Turn off GS15 plotter and GRAPHIX ADVANTAGE or other sign design system before checking connections or attempting to make any adjustments, unless otherwise directed.

  • Page 67: Z Axis (Tool Height) Adjustment

    Plotter Adjustment Z Axis (Tool Height) Adjustment SYMPTOMS The tool does not touch the material or touches only between characters. The knife does not cut deeply enough. The tool height changes in the middle of a job. OBJECTIVE To set the height of the lift fork for consistent contact of tool holder with material.
  • Page 68 plus 58 GS15 5. Locate the adjustment pad. There should be a gap of .003" to .010" (about the thickness of a piece of paper) between the pad and the cam shaft. If not, go to step 11. 6. If the gap is correct, remove the rear cover (with molded tool rack). Lay the plotter on its left side.
  • Page 69 Plotter Adjustment 8. Replace the rear cover. 9. Load paper in the plotter. 10. Turn on power. Run a multiple line test plot. 11. If symptoms persist, turn the plotter power off. 12. Rotate the cam shaft by hand until the lift fork is at its lowest position.
  • Page 70 22. Press the SLOW key to access the Square/Circle Test Plot. Press either RUN key to plot. Inspect your test plot by comparing to the Square/Circle Test Plot illustration. 23. If symptoms persist, return to step 1 or contact the Gerber Field Service Department at 800-828-5406, or fax at 203-645-2448.

  • Page 71: Theta Axis (Tool Rotation) Adjustment

    Plotter Adjustment Theta Axis (Tool Rotation) Adjustment SYMPTOMS Letters have jagged edges. Letters have closure problems of less than 1/32". The tool loses position in the middle of a job. OBJECTIVE To center lift fork over carriage spindle bore; to align tool holder in carriage spindle.
  • Page 72 plus 62 GS15 4. If the lift fork is not centered, use the Allen wrench from the tool kit to remove the two screws (shown below) at the front of the tool force housing cover. 5. Use a Phillips head screwdriver to remove the cover screw at the rear of the tool force housing (see below).
  • Page 73 Plotter Adjustment 6. Rotate the cam shaft by hand until the lift fork is at the point closest to the spindle. 7. Locate the two screws which hold the lift fork in place. Loosen these screws but do not remove them. 8.
  • Page 74 plus 64 GS15 14. Turn on the plotter power. After the spindle initializes, look under the carriage to note the position of the blade as it sits in the carriage spindle. The blade should be parallel with the two forks of the lift fork. The tip of the blade should point toward the left side of the plotter.
  • Page 75 RESET key. Load paper and install knife holder. 26. Press the down arrow to run the X08 test cut. Press either RUN key to cut. Inspect your test cut. If symptoms persist, call Gerber Field Service Department at 800-828-5406, or fax at 203-645-2448.

  • Page 76: Axis Belt Adjustment

    plus 66 GS15 X Axis Belt Adjustment SYMPTOMS Text cut in AXIS SWAP mode has closure problems. OBJECTIVE To adjust the tension of the X motor belt to produce good letter quality in AXIS SWAP mode. ADJUSTMENT PROCEDURE 1. Turn the plotter power off. 2.
  • Page 77 Plotter Adjustment 5. Pull the front cover upwards and, at the same time, pull one side away from the plotter frame. Be careful not to lift the cover so high that the front cable disconnects. Pivot the front cover to the side of the plotter.
  • Page 78 plus 68 GS15 7. If the X motor belt requires adjustment, locate the four X motor mounting screws (Phillips head screws). Loosen these screws, which hold the X motor bracket against the standoffs on the side plate. 8. Pull the motor up until the belt becomes tight. 9.

  • Page 79: Y Axis Backlash Adjustment

    Plotter Adjustment Y Axis Backlash Adjustment SYMPTOMS Text cut in NORMAL mode has closure problems. OBJECTIVE To adjust the mesh of the jack shaft gear with the Y motor pinion to produce good letter quality in NORMAL mode. ADJUSTMENT PROCEDURE 1.
  • Page 80 plus 70 GS15 4. Pull the front cover upwards and, at the same time, pull one side away from the plotter frame. Be careful not to lift the cover so high that the front panel cable disconnects. Pivot the cover to the side of the plotter.
  • Page 81 Plotter Adjustment 5. Locate the jack shaft gear and the Y motor pinion. These two gears are meshed together. Gently attempt to rotate the jack shaft gear. With one finger on the motor pinion, notice if the jack shaft gear moves while the pinion remains stationary.
  • Page 82 plus 72 GS15 8. While holding the motor bracket in place, tighten the two bracket screws. 9. Turn the plotter power on. 10. Load vinyl in the plotter, install the knife holder and cut a test plot. 11. If symptoms persist, return to step 1. 12.

  • Page 83: Drum End Play Adjustment

    This play exists because the ball bearing has a flexible race. If the amount of play does not exceed .005 inch and all check procedures in this section have failed to reveal the cause of the plotter's symptoms, contact Gerber Field Service Department at 800- 828-5406, or fax at 203-645-2448.
  • Page 84 plus 74 GS15 5. If there is more than .003 to .005 inch of play, remove the front plus cover. Lay the GS15 on its left side and remove the (2) Phillips head screws on the bottom edge closest to the front of the plotter. Then stand the plotter upright.
  • Page 85 Plotter Adjustment 11. Locate the centerline of the frame. Slide the plotter drum and the X axis gear toward the centerline of the frame and each other. Tighten the X axis drum clamp. 12. Slowly rotate the X axis gear two revolutions. Then rotate the X axis gear a quarter turn in the opposite direction.
  • Page 86 plus 76 GS15 16. After the adjustment is correct, reinstall the X motor. To do so, place the X motor on its standoff. Make sure the cable extends upward toward the ceiling. 17. Loosely install the three screws removed in step 8. Each must have a #8 lock washer and #8 flat washer.
  • Page 91 Plotter Adjustment plus GS15 PLOTTER USER REFERENCE CARD KEY/FUNCTION DESCRIPTION RUN SINGLE Key plus Plot Press RUN SINGLE to plot single jobs. The GS15 returns to the off-line status (as at power-up) after each job and waits for the operator to press RUN SINGLE key again to plot the next job.
  • Page 92 Z axis error Turn off the system; check connectors. Theta home failure Turn off the system; check connectors. plus Note: If the GS15 consistently fails the self-check tests, contact Gerber Field Service Department. plus SUGGESTED GS15 TOOL FORCE SETTINGS Material Recommended...
  • Page 93 Plotter Adjustment INDEX Add Plotter ........12 INIT KNIFE key......36 Adjustment Initial setting at power-up ..10, 33 drum end play ......73 Installation theta axis (tool rotation) ...61 pen holder.........22 X axis backlash......66 plotter .........7 Y axis backlash......69 pounce wheel holder ....25 Z axis (tool height) ....56 Jagged edges, character ....61 Arrow keys ........35...
  • Page 94 continuous exercise ....39 settings........29 single exercise ......38 Tool height adjustment....57 Square/Circle test plot42, 44, 45, 60 Tool rack, molded ....21, 25 Wagon Wheel test plot ..43, 60 Tool rotation adjustment ....61 Plotter ...........56 Troubleshooting ......56 adding plotter......12 Vinyl..........15 assign default plotter ....13 Wagon Wheel test plot ...43, 60 delete plotter ......12 X axis...
  • Page 95 151 Batson Drive Manchester, CT 06040 U SA Rev B P57347A...

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