Page 1 Digital flatbed cutter G3 series (M-1600, M-2500, L-2500, L-3200, XL-1600, XL-3200, 2XL-1600, 2XL-3200, 3XL-1600, 3XL-3200) Operating manual...
Page 2 Original operating instructions Author Technical Communications Department, Zünd Systemtech- nik AG Composition and publication Zünd Systemtechnik AG © Copyright Zünd Systemtechnik AG Version: Menu version: 1.45 05-2010 Date: 5106015 Doc. no.:...
Page 3 G3 series Contents Introduction ..........1 Foreword .
Page 4 G3 series Environmental conditions ........19 2.8.3 Basic device compressed air .
Page 5 G3 series Controls and operation ........1 General .
Page 6 G3 series Saving tool-specific cutter settings 4.7.6.4 ......32 Inserting and connecting a tool (e.g. oscillating tool) ....33 4.7.7 Connecting driven tools - allocating port .
Page 7 G3 series Cleaning and maintenance ........1 General .
Page 8 G3 series 000017,03,06-2009, jmu...
Page 9 We are therefore grateful for any comments or suggestions on how we can improve. Contact Zünd Systemtechnik AG Industriestrasse 8 CH - 9450 Altstätten Tel. ++41 71-757 8181 ++41 71-757 8191 info@zund.com mail zund.com 000009,06,11-2009, jmu...
Page 10 Introduction G3 series Using the documentation Using the documentation The instruction handbook supplied is intended to help you to: – Operate the machine safely – Perform routine machine maintenance – Use the machine optimally in all permitted areas To do this, you need to be able to find what you want within the documentation. The instruction handbook comprises: Volume 1 - Operating manual This volume contains information on the engineering, installation, operation and...
Page 11 G3 series Introduction Using the documentation 1.2.2 Symbols Illustration Close, fix, tighten, in Open, release, loosen, out Higher Lower Text structuring Task: Steps to perform Result: Outcome of the tasks performed. Prerequisites for performing a task List of tools Optional accessories There are a number of optional accessories available for the machine.
Page 12 Introduction G3 series Points to note when reading this operating manual Points to note when reading this operating manual Text references Chapter headings are numbered consecutively, with the first figure corresponding to the chapter number. Where reference is made to sections outside the current chapter, note the first figure and turn to the corresponding chapter, which contains the cited section.
Page 13 G3 series Introduction Current status of documentation Current status of documentation Act accordingly to make sure that the documentation is complete and up-to-date at all times: – Do not remove parts of the documentation – Request copies of missing or illegible pages from the manufacturer, or download and print them from the Zünd homepage –...
Page 14 Introduction G3 series Standardisation, tests, marking Machinery Directive 2006/42/EC and/or without CE marking. As a result, the declaration of conformity must be issued again by the purchaser. 1.6.3 UL testing Zünd G3 cutters have been UL tested and comply with the ISO 60950 standard. The certification can be accessed under UL number E176661.
Page 15 Offenders will be liable for damages. Troubleshooting, hints and tips Important! You can find information about troubleshooting and useful hints and tips on the Zünd homepage. (www.zund.com) Documented cutter models This documentation applies for the following types of G3 series cutters. G3 series...
Page 16 Introduction G3 series Publishing details 000009,06,11-2009, jmu...
Page 17 G3 series Product description General Product description General This chapter contains information on the following: – Representational conventions in the operating manual – Possible uses of the machine – Structure of the main components – Important technical data – General technical description of the device Directional information Directions such as "right, left"...
Page 18 Product description G3 series Product identification Product identification 2.2.1 Rating plate Important! The rating plate is used to uniquely identify your machine. Fig. 2-2 Position of rating plate 1 Manufacturer 5 Year of manufacture 2 Product category 6 CE marking 3 Device type 7 Manufacturer's address 4 Serial number...
Page 19: Intended Use
G3 series Product description Intended use 2.2.2 UL marking Fig. 2-3 UL marking 1 UL marking (Canada, USA) 3 Max. current 2 Voltage range 4 Frequency Intended use The cutter system can be used for the following purposes: – As an output device for CAD/CAM data –...
Page 20 Product description G3 series Cutter - overview Cutter - overview Fig. 2-4 Cutter - overview 1 Work station 8 Power unit 2 Cutter extension, front 9 Right-hand safety device 3 Table with vacuum 10 Electronics unit 4 Left-hand safety device 11 Vacuum generator 5 Bar 12 Extractor (optional)
Page 21 Zünd offers tools for processing the most wide ranging materials. A selection of important tool inserts can be found under the corresponding module. On the Zünd homepage (www.zund.com) you can find all the current tool inserts or contact your Zünd partner for detailed information.
Page 22 Product description G3 series Modules, tools 2.5.2.1 Tools for the UM POT: Pneumatic oscillating tool for thick or tough materials such as foam, filling materials, thick leather, upholstery fabrics etc. EOT: Electrical oscillating tool for cutting soft to average toughness materials. DRT: Driven tool for rotating knives for cutting textiles, fibrous materials such as Kevlar, carbon VCT: Cutting tool for producing V-cuts...
Page 23 G3 series Product description Modules, tools 2.5.3 RM-A Router module for the use of 1000 W Zünd motor spindles. Motor spindle with 1000 W for the processing of the most wide-ranging materials. 2.5.4 Punching and stamping module for the processing of leather materials.
Page 24 Product description G3 series Modules, tools 2.5.5 MAM-S/D Single/double marking module for use of ballpoint pens and other marking inserts. 000003,07,05-2010, jmu...
Page 25 G3 series Product description Material handling, options Material handling, options 2.6.1 Laser pointer The laser pointer is used as an aid for the precise definition of the reference point 2.6.2 ICC camera The ICC camera is used as an aid for importing the registration marks.
Page 26 Product description G3 series Material handling, options 2.6.4 Cutter with conveyor Conveyor systems are used for pulling the materials to be worked with. The conveyor belt is used as a cutting base and conveyor belt at the same time. During the processing, the material to be processed is fixed in place using a vacuum.
Page 27 G3 series Product description Material handling, options 2.6.6 Drip tray Catches cutting waste 2-11 000003,07,05-2010, jmu...
Page 28 Product description G3 series Technical description Technical description 2.7.1 Complete machine The G3 cutter is a variable processing system for flexible and rigid materials with various tool systems. Extension options are available to provide improved handling and for the adjustment of the system to special requirements or for processing specific materials.
Page 29 G3 series Product description Technical description 2.7.3 Complete machine Table/vacuum plate The work surface is designed as a perforated sheet. Vacuum zones are arranged under this perforated sheet which are connected to a high-performance vacuum generator via a distributor. The vacuum is used for holding down and tightening the material to be processed. The cutter control permits sequential activation/deactivation of the individual vacuum zones and therefore reduces energy consumption.
Page 30 Product description G3 series Technical description 2.7.4 Movement system The G3 series has four electronically driven axes. Axis Function Movement system Drive via toothed belt/steel belt Material transport, material Feed clamp elements, feeding transport extension clamps, auxiliary drive Movement of the module Drive via toothed belt/steel belt carriage Height adjustment of the...
Page 31 G3 series Product description Technical description 2.7.5 Processing materials The multitude of materials which can be processed with the different module and tool systems means that there is no single way to achieve the target. However, the following factors always play an important role and must always be set/ selected for the specific material: •...
Page 32 Width B1 Width B2 Height (D x E) [mm] (B x C) [mm] [mm] [mm] Work surface (A) [mm] M-1600 1330 x 1600 2055 x 2512 M-2500 1330 x 2500 2055 x 3412 L-2500 1800 x 2500 2525 x 3412...
Page 33 G3 series Product description Technical information Type Static material clea- Material clearance Material clea- (D) [mm] rance width width with CV (D) rance thickness [mm] [mm] M-1600 1610 1330 M-2500 1610 1330 L-2500 2080 1800 L-3200 2080 1800 XL-1600 2550...
Page 34 Product description G3 series Technical information 2.8.1.2 Cutter extension Important! Cutter extensions do not increase the work surface of the cutter. They serve as a transport belt extension for the feeding and removal of material Fig. 2-10 Cutter extension dimensions Cutter extension T1 [mm] Type...
Page 35 G3 series Product description Technical information 2.8.2 Electrical connection, power consumption Electrical connection 400 V, 50/60 Hz Value Units Voltage 3-phase, 400 L1, L2, L3, N, PE Mains frequency 50/60 Hz Power consumption - 3 phases(without 3.6 KW vacuum generator) Current consumption, 3 phases(without max.
Page 36 Product description G3 series Technical information Conveyor feeding clamps Value Units Setting - pressure regulator maintenance unit 0.6 MPa (P3) Control of vacuum zones, supply of various Value Units modules, tools Operating pressure 0.6 - 0.8 MPa Min. air flow 20 l/min Setting - pressure regulator maintenance unit 0.6 MPa...
Page 37 G3 series Product description Technical information 2.8.6 Performance Precision Value Units Resolution of measuring system 0.005 mm Positioning accuracy at a constant temperature ± 0.1 mm Repeat accuracy ± 0.03 mm Evenness of the table ± 0.2 mm Cutting performance Value Units Speed in the vector direction...
Page 38 Product description G3 series Technical information 2.8.7 Emissions Noise Continuous sound pressure level of the cutter < 75 dB (A) Depending on the tool system and materials to be processed: – if the limit value of 85 dB (A) is exceeded, –...
Page 39 G3 series Safety General Safety General Your safety – as the operator, service engineer or otherwise – is the primary concern. Certain situations, problems or faults that may occur on the equipment could put your safety at risk if you are not aware of the steps you should take to avoid the resulting dangers.
Page 40 Safety G3 series Proper use Proper use The proper use of the machine is essential for its safe operation. The equipment supplied: • Is listed and labelled • Determines the possible uses of the machine The machine is intended for use as an output device for CAD/CAM data for the labelling and processing of materials arranged on the table.
Page 41 G3 series Safety Hazard warnings, important instructions Hazard warnings, important instructions 3.4.1 Explanation of the hazard warning Both in the operating manual and on the device itself, dangers, important instructions and user tips are designated by special symbols and signal words as follows. Danger! The safety instruction Danger •...
Page 42 Safety G3 series Hazard warnings, important instructions 3.4.2 Structure of the hazard warnings Example: Warning! Risk of poisoning from the emission of toxic dust Processing certain materials can lead to the creation of toxic dust with significant risk to health. •...
Page 43 G3 series Safety Areas of responsibility Areas of responsibility The manufacturer • Is responsible for the safe condition of the machine on delivery, including instruc- tion handbook and accessories, according to the sales documentation. The owner or person authorised by him: •...
Page 44 Safety G3 series Rules and safety at work Rules and safety at work • The operation of the machine is always subject to local regulations regarding sa- fety at work and accident prevention. • Before the machine is put into operation: Always check the safety equipment and protective covers.
Page 45 G3 series Safety Danger areas Danger areas 3.9.1 General danger area Fig. 3-1 General danger area 1 Danger area 000011,08,11-2009, jmu...
Page 46 Safety G3 series Danger areas 3.9.2 Danger area on the module carriage Attention! Risk of injury on the module carriage The danger area on the module carriage is not secured using safety devices. • Do not reach into the danger area during the manual initialisation •...
Page 47 G3 series Safety Danger areas 3.9.3 Danger area during the installation Attention! Risk of injury during the manual initialisation of the tool. The safety devices are not active during the manual initialisation • Do not reach into the danger area during the manual initialisation •...
Page 48 Safety G3 series Working and traffic area 3.10 Working and traffic area Warning! There is a danger of injury to others through inappropriate behaviour or carelessness. Please advise others to maintain an appropriate safety distance from the designated work and traffic zone. Fig.
Page 49: Safety Signs
G3 series Safety Safety signs 3.11 Safety signs 3.11.1 Responsibility of the operator Warning! Risk of injury due to a lack of safety signs Risks and sources of danger cannot be localised due to the lack of safety signs. • Replace missing or illegible safety signs as per Fig.
Page 50 Safety G3 series Safety signs Warning! Safety risks due to missing or illegible safety signs. Check all safety signs on a regular basis for legibility and completeness. Replace missing or illegible safety signs promptly with new original signs. Meaning of safety signs The symbols on the safety signs –...
Page 51 G3 series Safety Safety signs Warning signs – are triangular and yellow-coloured – Are intended to draw attention to objects and circumstances which represent a potential danger to life and limb. Danger of hand injuries (crushing) Danger of hand injuries (severing) Danger of electrical safety hazard Laser beam warning 3-13...
Page 52 Safety G3 series Safety and monitoring devices 3.12 Safety and monitoring devices Fig. 3-6 Safety and monitoring devices 1 Emergency stop switch 3 Operating unit 2 Protective system 3-14 000011,08,11-2009, jmu...
Page 53 G3 series Safety Safety and monitoring devices 3.12.1 Protective system Attention! If there is a collision, the bar may cause serious injuries. The high level of kinetic energy of the drive results in a braking distance which cannot be ignored. Light barriers and safety cut-offs are no guarantee against injuries.
Page 54 Safety G3 series Safety and monitoring devices 3.12.3 Emergency stop switch – Emergency stop switches are part of a protective circuit – They allow the machine to be turned off quickly in hazardous situations Two emergency stop switches can optionally be fitted on the edges of the machine. The mains power supply to the whole machine is switched off as soon as the emergency stop switch is pressed.
Page 55 G3 series Safety Personal protective equipment, clothing 3.13 Personal protective equipment, clothing The safety equipment required for operating the machine is dependent on the following factors: – The module and tool system – The material to be processed When operating the machine or carrying out maintenance or servicing work, wear close-fitting clothing and the appropriate personal protective equipment.
Page 56 Safety G3 series Mechanical hazards 3.14 Mechanical hazards 3.14.1 Gathering, retraction Hazards caused by the bar, modules or the tool system during gathering and retraction Possible consequences: • Cuts, bruising and crushing of fingers and hands • Bruising of head and arms •...
Page 57 G3 series Safety Risk of burns 3.14.3 Cuts and stab wounds Knives, routers and punching inserts have very sharp edges which are sometimes hidden by moving equipment (slipper spring). Possible consequences: • Cuts and stab wounds to the hands and arms Precautions during the knife change, initialisation and the operation in the ONLINE operating status of the machine: •...
Page 58 Safety G3 series Electrical hazard 3.16 Electrical hazard Warning! Risk of death or injury from electric shock. The machine is operated with a mains voltage of 380 V, system frequency of 50/60 Safety instructions • Only trained service personnel are authorised to open switch boxes and electro- nics units.
Page 59 G3 series Safety Risks arising from the emission of toxic dust 3.17 Risks arising from the emission of toxic dust Warning! Risk of poisoning from the emission of toxic dust Processing the most wide-ranging materials can lead to the creation of toxic dust with significant risk to health.
Page 60 Safety G3 series Environmental hazard 3.19 Environmental hazard Warning! Processing residues, operating fluids etc. can cause damage and pollute the environment if they enter the soil, watercourses or the sewage system. Explanation of the hazard label Hazard label for substances that are harmful to the environment Safety regulations and protective measures •...
Page 61 Important! Chemicals classed as irritants are used to operate and clean this machine (cleaning agents, operating fluids). Safety datasheets of the substances in question can be downloaded from the Zünd homepage (www.Zund.com). Safe handling of chemicals Disposal! Dispose of chemicals in accordance with national regulations.
Page 62 Safety G3 series Risk of fire and explosion 3.21 Risk of fire and explosion Warning! There is a risk of fire when routing and cutting inflammable materials Terminate the routing/cutting and leave the tool to cool in the case of •...
Page 63 G3 series Safety Danger caused by laser beam (laser pointer) In the event of a fire: • Switch off the machine (emergency stop switch) • Assess the situation: If the situation is dangerous, leave the area immediately and call the fire brigade. Only try to extinguish the fire if your personal safety is not at risk.
Page 64 Safety G3 series Safety precautions for service personnel 3.24 Safety precautions for service personnel The reliability, readiness and service life of the machine greatly depend on you carrying out your work in a conscientious manner. Important! Specialist knowledge and expertise are required to service and maintain the machine.
Page 65 G3 series Controls and operation General Controls and operation General This chapter familiarises you with the controls, guides you through the operational procedures and describes the following operating steps: – Daily commissioning – Operation of the main components – Detailed information on the operation of the machine –...
Page 66 Controls and operation G3 series Controls Controls 4.3.1 Control panel Fig. 4-1 Control panel 1 Switch unit 3 Operating unit 2 Emergency stop switches 000010,10,05-2010, jmu...
Page 67 G3 series Controls and operation Controls 4.3.1.1 Operating unit Fig. 4-2 Operating unit STOP 1 Display ONLINE 2 Soft keys SHIFT 3 Navigation keys 4 Numerical keys 10 Travel keys Tool up/down key (vacuum) 6 Coordinate system (axes) 12 Function keys 000010,10,05-2010, jmu...
Page 68 Controls and operation G3 series Controls 4.3.1.2 Navigation keys Fig. 4-3 Navigation keys Function in the cutter menu Use these keys to navigate through the menu • If submenus are available, use this key to change to the next menu level •...
Page 69 G3 series Controls and operation Controls 4.3.1.5 Travel keys Fig. 4-6 Travel keys, shift key 1 Move module forwards 4 Move module to the right 2 Move module to the left 5 SHIFT key 3 Move module backwards These keys are used to move the module unit in the operating statuses STOPPED and OFFLINE.
Page 70 Controls and operation G3 series Controls 4.3.1.7 Special keys, shortcuts Important functions are defined with separate keys on the operating unit: Function Current operating status With SHIFT key Without SHIFT key STOPPED Switch off the machine Change to OFFLINE ONLINE Switch off the machine Change to STOPPED OFFLINE...
Page 71 G3 series Controls and operation Controls 4.3.2 Emergency stop switches Attention! Risk of damage to the machine. Only use the emergency stop switches to switch off the machine in an emergency - not for standard shutdown. • Emergency stop switches are part of a protective circuit •...
Page 72 Controls and operation G3 series Controls Important! An emergency stop switch that has been pressed remains locked in the off position. To unlock an activated emergency stop switch after regaining operational safety, turn the switch anti-clockwise. Procedure ⇨ When a hazard or a possibly hazardous situation occurs, press an emergency stop switch without delay ✓...
Page 73 G3 series Controls and operation Controls 4.3.3 Maintenance unit The maintenance unit adjusts the air pressure to the switching of the vacuum elements/various modules and options. Fig. 4-9 Maintenance unit 1 Stopcock 4 Air pressure setting for conveyor clamp elements and feed elements (P3) 2 Water separator 5 Fixing bracket for an additional, optional 3 Air pressure setting for various...
Page 74 Controls and operation G3 series Controls 4.3.4 Interfaces The machine has interfaces for data exchange. These are attached to the electronics unit. Fig. 4-10 Interfaces 1 LAN 4 Status and error display 2 Not used 5 COM 1 3 USB (Host) 6 COM 2 4-10 000010,10,05-2010, jmu...
Page 75 G3 series Controls and operation Menu navigation Menu navigation 4.4.1 Menus and functions Navigation The cutter has a large number of functions. The current menu number and the current menu are displayed in the header. Fig. 4-11 Current menu number, menu Graphic layout Symbol Description...
Page 76 Controls and operation G3 series Menu navigation Value/entry ⇨ If a flashing cursor appears on the display below a number, then a number input is required ⇨ Enter the required value using the numerical keys ⇨ Check the value and confirm using OK or cancel the entry using ESC Select ⇨...
Page 77 G3 series Controls and operation Menu navigation 4.4.2 Help Help texts are available for important menu entries. In order to display a help text, mark the required menu and press the key. 4.4.3 Info menu Within the menu the Info menu can be activated with the key.
Page 78 Controls and operation G3 series Menu navigation 4.4.5 User level Access to menus and functions is blocked according to the user level. The user levels have a hierarchical structure. This means that the next highest user also has the access rights to the menu functions that the subordinate user has. User level Description Users 1 - 3...
Page 79 G3 series Controls and operation Menu navigation 4.4.6 Function keys The cutter has function keys (F1 - F8) which can be allocated menu functions. These keys can be selected via the menu or directly. Allocate function keys directly ⇨ Press the SHIFT key and the function key (F1 - F8) which you wish to change at the same time ⇨...
Page 80 Controls and operation G3 series Functions Functions 4.5.1 Set language It is possible to select the display language of the cutter. Language ⇨ Select the function from the menu ⇨ Select the required language from the list and confirm 4.5.2 Set display Setting the contrast Description...
Page 81 G3 series Controls and operation Operation Operation 4.6.1 Daily checks prior to start-up Attention! There is a risk of injury if the machine is defective. Faults on the machine may be the cause of malfunctions and accidents - never start up a defective machine.
Page 82 Controls and operation G3 series Operation 4.6.2 Start-up Switching on the machine Fig. 4-12 Switching on the machine ⇨ Switch the main switch to position ON (1) ✓ The cutter switches on. The start page appears on the display 4-18 000010,10,05-2010, jmu...
Page 83 G3 series Controls and operation Operation Initialising the machine Attention! ⇨ Risk of injury due to automatic starting of the machine ⇨ Following initialisation, the operating status OFFLINE is active. The cutter can receive commands from the operation software which activate the operating status ONLINE.
Page 84 Controls and operation G3 series Operation 4.6.3 Operating status The cutter can be switched into three operating statuses depending on the purpose: – OFFLINE – ONLINE – STOPPED A combination of keys can optionally be used to switch from any operating status to either of the other two operating statuses.
Page 85 G3 series Controls and operation Operation 4.6.3.1 OFFLINE Attention! Risk of injury due to automatic starting of the machine In the OFFLINE operating status, the cutter receives commands from the operating software. These commands can be used to switch to the operating status ONLINE. •...
Page 86 Controls and operation G3 series Operation 4.6.3.3 ONLINE A green illuminated LED on the ONLINE key indicates that the operating status ONLINE is active. Commands are received and processed in this operating status. ⇨ must be pressed in order to activate the operating status ONLINE. The displays shows the following message: ⇨...
Page 87 G3 series Controls and operation Operation 4.6.4 Moving the bar/module manually Fig. 4-14 Moving the bar/module The module carriage can be moved using the travel keys in the operating status OFFLINE. The assignment of keys corresponds to the direction of travel. Pressing the SHIFT key at the same time will make the module carriage move faster.
Page 88 Controls and operation G3 series Handling modules/tools Handling modules/tools Modules are independently recognised by the cutter control unit. Tools, on the other hand, do not have automatic recognition and must be manually allocated to a module. Tool-specific parameters (initialisation, moving speeds, acceleration) are saved to the corresponding tool and can be called up again at any time.
Page 89 G3 series Controls and operation Handling modules/tools 4.7.1 Module/tool/tool insert Fig. 4-16 Module carriage/module/tool/blade, router, etc. 1 Module (e.g. RM, UM) 2 Tool (e.g. 1000 W motor spindle, oscillating tool) 3 Module carriage (e.g. 3-way) 4 Router, blade, etc. 4-25 000010,10,05-2010, jmu...
Page 90 Controls and operation G3 series Handling modules/tools 4.7.2 Set module/tool change position (can be set at operator user level or higher) Fig. 4-17 Example: module carriage position for changing the module 1 Example: module carriage position 1 for changing standard modules 2 Example: module carriage position 2 for changing RM-A Any two positions can be selected for module changes.
Page 91 G3 series Controls and operation Handling modules/tools 4.7.3 Inserting/replacing the module 4.7.3.1 Module mount Fig. 4-18 Module mount 1 Locking mechanism 3 Electrical connection 2 Mounting ledge 4-27 000010,10,05-2010, jmu...
Page 92 Controls and operation G3 series Handling modules/tools 4.7.3.2 Inserting/replacing the module (e.g. UM) Fig. 4-19 Inserting a module Change module/tool ⇨ Select 1-5-1. The module carriage moves to the module change position. ⇨ Place the module on the mounting ledge as in Fig. 4-19, step A. ⇨...
Page 93 G3 series Controls and operation Handling modules/tools 4.7.4 Activating a module It is often useful to activate a module/tool in order to check settings. This function can only be carried out in the main menu. ⇨ Activate the required module. Module Key combination Module 1...
Page 94 Controls and operation G3 series Handling modules/tools 4.7.5 Tool handling 4.7.5.1 Marking the tool (e.g.) Fig. 4-20 Marking the tool (e.g.) ⇨ Label all tools of the same type with a consecutive number. Appropriate adhesive labels are supplied with the equipment. 4.7.5.2 Switching the tool manager on/off The tool manager is a user interface for handling tools in combination with a universal module (UM).
Page 95 G3 series Controls and operation Handling modules/tools 4.7.5.3 Tool manager — change tool (UM module) Change module/tool ⇨ Select 1-5-1. ⇨ If necessary, select the module/tool change position. ⇨ Insert the tool and connect the power supply if it is driven electrically or pneumatically.
Page 96 Controls and operation G3 series Handling modules/tools 4.7.6 Attaching/selecting a tool 4.7.6.1 Creating a new tool ⇨ Insert the marked tool into the module. Tool type ⇨ Select 1-1-1-1 in the menu. ⇨ Select NEW Create new entry ⇨ The popup menu opens Tool type ⇨...
Page 97 G3 series Controls and operation Handling modules/tools 4.7.7 Inserting and connecting a tool (e.g. oscillating tool) Ensure, that following preconditions are fulfilled: ❏ The machine is switched off and is in the operating status STOPPED ❏ The module is now mounted and has been located by the control unit Fig.
Page 98 Controls and operation G3 series Handling modules/tools 2 Module lock 5 Positioning bracket 3 Connector socket Important! The tool holder and a holding fixture are each marked with a red dot. The tool is in the correct position when the dots are aligned. ⇨...
Page 99 G3 series Controls and operation Handling modules/tools 4.7.8 Connecting driven tools - allocating port Driven tools (e.g.: EOT, DRT, POT) require an energy supply (electrical, pneumatic). This energy supply is controlled by the cutter control unit. Electrically driven tools are inserted into the intended port on the connector control of the laser pointer/ICC camera.
Page 100 Controls and operation G3 series Handling modules/tools 4.7.8.2 Connection - pneumatic tools Pneumatically driven tools and modules are connected to the interface unit on the module carriage. The pressure is set using a maintenance unit. The air supply is connected to the local installation or supplied via a compressor. The connection data and connection procedure may be found in the operating instructions for the appropriate tool/module.
Page 101 G3 series Controls and operation Handling modules/tools 4.7.9 Tool positions Example: EOT/POT/universal cutting tool After initialisation, 3 tool positions are possible. Fig. 4-24 Tool positions Item Position Description Signal Park position Moves to the highest position on the Z axis Up Z pos Zero point + Up Z pos...
Page 102 Controls and operation G3 series Material hold-down Material hold-down The material is held down via a vacuum. For this purpose, the machine table is divided into 0 - X vacuum zones. The number of zones is dependent on the size of the cutter.
Page 103 G3 series Controls and operation Material hold-down 4.8.1 Preparation Cover the excess vacuum surface in order to achieve optimum material hold-down during the processing procedure. Fig. 4-26 Defining the vacuum range 1 Processing material 2 Covering the excess vacuum area ⇨...
Page 104 Controls and operation G3 series Material hold-down 4.8.2 Defining/checking the vacuum range Fig. 4-27 Defining the vacuum range Defining the vacuum range Fixing ⇨ Use the key to switch to menu 3-1. ⇨ Select function Vacuum range 3-1-1-7 ⇨ Use the travel keys to approach the left edge of the material to be processed ⇨...
Page 105 G3 series Controls and operation Material hold-down Checking the range Fixing ⇨ Use the key to switch to menu 3-1. Vacuum range ⇨ Change to the submenu 3-1-1-7 Move to vacuum ⇨ Select the function 3-1-1-7-4 ⇨ Choose OK to confirm ✓...
Page 106 Controls and operation G3 series Feeding options* Feeding options* The Zünd feed system allows the material to be processed to be transported on with a conveyor belt following a completed work process. The conveyor belt is gripped and fed using two clamping elements, while the material to be processed is fixed with feeding clamps/a feed guide rail.
Page 107 G3 series Controls and operation Feeding options* 4.9.1 Feeding clamps Fig. 4-29 Feeding clamp 1 Feeding clamp 2 Compressed air on/off 3 Screw for fixing the feeding clamps Setting the feeding clamps ⇨ Loosen the screw for fixing the feeding clamp ⇨...
Page 108 Controls and operation G3 series Feeding options* 4.9.2 Feed guide rail Fig. 4-30 Feed guide rail 1 Screw for fixing the feeding clamp 2 Feed guide rail 3 Fastening screw, self-locking Assembling the feed guide rail ⇨ Use SHIFT to switch the cutter off ⇨...
Page 109 G3 series Controls and operation Feeding options* 4.9.3 Feeding options The feed is controlled via the communication software. The following factors can be preset via the cutter control unit (see chapter "Menu description") and must be set for the specific material: –...
Page 110 Controls and operation G3 series Automatic tool initialisation (AKI) 4.10 Automatic tool initialisation (AKI) Important! Manual initialisation is described in the operating manual of the relevant tool. See chapter "Tools". 4.10.1 Description The following tools can be initialised using the automatic tool initialisation: –...
Page 111 G3 series Controls and operation Automatic tool initialisation (AKI) 4.10.2 Adjusting the height Important! Ensure that the automatic tool initialisation lies planar on the cutting base (conveyor belt). Adjust the height if necessary. Fig. 4-32 Adjusting the height 1 Automatic tool initialisation 3 Table 2 Cutting base 4 Adjusting screw...
Page 112 Controls and operation G3 series Automatic tool initialisation (AKI) 4.10.3 Initialisation Example: Module 2; electrical, oscillating tool Fig. 4-33 Initialisation ⇨ Use the travel keys to move the module into the centre of the cutter ⇨ Remove the automatic tool initialisation from the holder and position it in the guide on the table ⇨...
Page 113 G3 series Controls and operation Laser pointer, reference point 4.11 Laser pointer, reference point Attention! Laser class 2. Looking directly into laser beam will damage the eyes. Avoid looking directly into the laser beam. The laser pointer is an optical instrument for visually determining the reference point. It is attached to the module.
Page 114 Controls and operation G3 series Laser pointer, reference point 4.11.2 Reference point settings A reference point can be defined on the working area of the cutter. This reference point is the starting point for the processing procedure and corresponds to the zero point of the processing file. Fig.
Page 115 G3 series Controls and operation Laser pointer, reference point 4.11.3 Choose laser pointer as pointer type Both the current tool and the laser pointer can optionally be defined as the pointer for defining the reference point. Pointer type ⇨ Select the function 1-5-2-1-1 ⇨...
Page 116 Controls and operation G3 series Material stop 4.12 Material stop Important! Damage to tool inserts, tools and modules. • Remove the material stop after positioning the processing material. The material stop serves as an aid for positioning the processing material at the zero point.
Page 117 G3 series Controls and operation Module carriage slot protective plate 4.13 Module carriage slot protective plate Attention! Risk of being crushed The module carriage area is not monitored by safety devices. • Do not reach into the active area of the cutter during operation •...
Page 118 Controls and operation G3 series Module and tool holder* 4.14 Module and tool holder* Attention! Always store any unused tools and modules correctly, in order to avoid any damage to them. Store any unused modules and tools in the module and tool holder. The module and tool holder has space for two tools and two modules.
Page 119 G3 series Controls and operation Switch off the machine 4.15 Switch off the machine To switch off the machine, proceed as follows: ⇨ Switch the cutter into the operating status OFFLINE Shut down cutter ⇨ Select the function from the menu or press the key combination SHIFT + ⇨...
Page 120 Controls and operation G3 series Switch off the machine 4-56 000010,10,05-2010, jmu...
Page 121 G3 series Description of menu General Description of menu Valid from firmware 1.45 General The menu description contains all menu entries and commands. However, entries which repeat periodically (module 1 - module 4) are only listed once. Explanations on module/tool-specific menu entries can be found in the operating manual of the respective module/tool insert.
Page 122 Description of menu G3 series Description of menu Description of menu 1160 Main menu Highest level of the menu structure Highest level of the menu structure Cutter setup Main menu for the configuration of the cutter The following settings for the configuration of the cutter are carried out in this menu: –...
Page 123 G3 series Description of menu Description of menu 1-1-1 Tool pos. 1 No help text is available for this menu. Fig. 5-2 Tool slot, tool assignment e.g. Module 2, tool 1 1 Module 2 (UM) = tool slot 2 = Tool pos. 1 2 Oscillating tool = tool 1 Each module consists of up to four tools (e.g.
Page 124 Description of menu G3 series Description of menu 1-1-1-1 Select tool No help text is available for this parameter. Assign the tool that is used in the module. For the attachment/selection of a new tool see chapter "Controls and operation", "Tool handling"...
Page 125 G3 series Description of menu Description of menu Fig. 5-3 Init height ⇨ Select function ⇨ Use the travel keys to move to the suction height and confirm the dialogue using 1807 1-1-1-3 Tool setup No help text is available for this menu. Tool-specific settings.
Page 126 Description of menu G3 series Description of menu Two converters (RM) available; either converter 1 or converter 2 can be assigned to the spindle. Select converter 1 or 2 as the converter for this module. 3339 1-1-1-3-1-1 Infeed angle No help text is available for this parameter. 0°...
Page 127 G3 series Description of menu Description of menu 3129 1-1-1-3-1-6 Continuous Path No help text is available for this parameter. Continuous path switched on The speed is the same in all directions. The speed can be calculated using the setting Down X&Y value from 1-1-1-3-2-2.
Page 128 Description of menu G3 series Description of menu Important! • The quality setting corresponds with the HPGL command, QU. • If the quality is set via this menu, the following parameters are automatically op- timally set: acceleration, circle res. • Send the circle data as an arc function! Selection Description...
Page 129 G3 series Description of menu Description of menu 1-1-1-3-3 Accel. settings Setting of the tool acceleration. Setting of the tool acceleration. The maximum possible acceleration depends on the following factors: • Table size • Module carriage weight 2038 1-1-1-3-3-1 Up X&Y Acceleration of the tool in the X/Y direction when the tool is raised Acceleration of the tool in the X/Y direction when the tool is raised Setting range: Levels 1-4...
Page 130 Description of menu G3 series Description of menu Pressure mode: The cutting depth is the result of a set pressure which is exerted on the tool by the module. The module moves into the material until the preset pressure is reached. Initialisation generally takes place on the material surface.
Page 131 G3 series Description of menu Description of menu Correction factor for setting the processing depth. This value can be used to adjust the cutting depth by ±1.5 mm. 1774 1-1-1-3-4-9 Init Z pos No help text is available for this parameter. Define Z init Z position after initialisation.
Page 132 Description of menu G3 series Description of menu 1-1-1-3-6 Tool delay settings No help text is available for this menu. Setting of the tool-specific delay times. 1859 1-1-1-3-6-1 Before down delay Delay time in ms before the module is lowered. Delay before lowering the tool 1860 1-1-1-3-6-2...
Page 133 G3 series Description of menu Description of menu Example: Cutting diagram with all correction Cutting diagram once the alignment values set to 0 process has been successfully 1 Start of cut (penetration point) completed 2 End of cut Preparation ⇨ Place paper on the cutting support ⇨...
Page 134 Description of menu G3 series Description of menu Correct Y When the axes are aligned, the cuts are moved towards the coordinate system axes until each of the parallel cuts lie on the same axis. Measure and calculate distance a (mm/in) of the parallel cuts to the X axis as follows: Test cut ⇨...
Page 135 G3 series Description of menu Description of menu Correct X When a centre alignment is carried out, the cuts are moved towards the coordinate system centre until the cut and the coordinate system are congruent. Measure and calculate distance b (mm/in) (penetration point line 1 to penetration point line 2) of the parallel cuts to the X axis as follows: Test cut ⇨...
Page 136 Description of menu G3 series Description of menu Fig. 5-7 Tool slot, tool assignment e.g. Module 2, tool 1 1 Module 2 (UM) = tool slot 2 = Tool pos. 1 2 Oscillating tool = tool 1 Each module consists of up to four tools (e.g. PUM). The first figure of the menu entry shows the tool slot of the module, the second figure shows the tool position.
Page 137 G3 series Description of menu Description of menu The allocations and settings of the tools are carried out in the following submenus. Module 2 No help text is available for this menu. Menu with settings for module 2. Fig. 5-9 Module 1 - 3 1658 1-2-1 Tool pos.
Page 138 Description of menu G3 series Description of menu 1-2-2 Tool pos. 2 2 No help text is available for this menu. See tool pos. 1 1 1-2-3 Tool pos. 2 3 No help text is available for this menu. See tool pos. 1 1 Module 3 No help text is available for this menu.
Page 139 G3 series Description of menu Description of menu Each module consists of up to four tools (e.g. PUM). The first figure of the menu entry shows the tool slot of the module, the second figure shows the tool position. The menu entries of the tools 11 - 14; 21 - 24; 31 - 34; (41 - 44)* are identical. The allocations and settings of the tools are carried out in the following submenus.
Page 140 Description of menu G3 series Description of menu AUTO is usually used to automatically determine the optimum shutter speed. 3618 1-5-2-2-5 White balance No help text is available for this parameter. auto Room light Fl. light Setting of the white balance. AUTO is usually used to automatically determine the optimum white balance.
Page 141 G3 series Description of menu Description of menu No help text is available for this parameter. Display/input the X-coordinates of position 1. 3959 1-5-7-4 Position 1 Y No help text is available for this parameter. Display/input the Y-coordinates of position 1. 3954 1-5-7-5 Position 2...
Page 142 Description of menu G3 series Description of menu Table No help text is available for this menu. General table settings 2498 1-6-1 Park options No help text is available for this menu. The parking function is linked to the HP-GL command "PK" in the ONLINE operating status.
Page 143 G3 series Description of menu Description of menu 1-6-1-4 X park pos Position after the cutter starts and stand-by position. Definition of the X coordinates of the park position 2500 1-6-1-5 Y park pos Position after the cutter starts and stand-by position. Definition of the Y coordinates of the park position 2470 1-6-2...
Page 144 Description of menu G3 series Description of menu Free The light barrier is not interrupted Interrupted The light barrier is interrupted 3191 1-6-2-5-3 Reflex LB left No help text is available for this parameter. Free Interrupted Error Testing the front light barrier. Error Light barrier defective Free...
Page 145 G3 series Description of menu Description of menu Vacuum + Stop: – The bar moves to the rear. – The feeder elements hold down the material – Stand-by position is approached – Remove the cut material from the table. – The material feed is carried out once the mes- sage has been confirmed.
Page 146 Description of menu G3 series Description of menu 1-7-2-1 Transport to the front No help text available Important! A transport to the front can only be executed when the feed system is correspondingly configured. A feed is executed. Starting point: current position End point: X = 0 3754 1-7-2-2...
Page 147 G3 series Description of menu Description of menu Switch on wind-up unit 3310 1-7-4-2 Wind-up unit off Automatic initialisation with AKI Switch off wind-up unit 2870 1-7-6 Ext. material handling 1 No help text is available for this menu. Settings for external material handling 1 3903 1-7-6-1 Ext.
Page 148 Description of menu G3 series Description of menu 1-7-18 Manual feed table No help text is available for this menu. Functions for setting the manual feed table. 3139 1-7-18-1 Manual feed table No help text is available for this parameter. Activate/deactivate the stop of the manual feed table.
Page 149 G3 series Description of menu Description of menu 1-8-2 Vacuum pump options No help text is available for this menu. Setting of the gas ring vacuum generator 2548 1-8-2-1 Status No help text is available for this parameter. Activating/deactivating the vacuum generator 2546 1-8-2-2 Start time...
Page 150 Description of menu G3 series Description of menu Automatic initialisation with AKI Move to the end of the active vacuum zone. The active tool moves to the end of the active vacuum range or to the last active vac- uum zone. 2925 1-8-3-5 Active zones...
Page 151 G3 series Description of menu Description of menu Job setup Main menu for the job settings. Settings relating to the current job 1610 Reference point settings No help text is available for this menu. Two reference points (start points) can be defined on the work surface. The reference point automatically determined by the machine during start-up is deactivated following the activation of a reference point.
Page 152 Description of menu G3 series Description of menu Menu item has no content. 1616 2-4-1-6 Centre Y rotation No help text is available for this parameter. Menu item has no content. 1885 2-4-2 Offset No help text is available for this menu. Move output in X/Y direction 1611 2-4-2-1...
Page 153 G3 series Description of menu Description of menu This function moves the head along the limits of the clipping window. Move along the window limits? Display of the window limits is running... Display of the window area. The limits of the activated window are shutdown. 2002 2-6-1-5 Top left X...
Page 154 Description of menu G3 series Description of menu 3-1-1 Vacuum Menu for setting and changing the vacuum. Setting the material hold-down by vacuum. 1989 3-1-1-1 Vacuum status No help text is available for this parameter. Suction Blowing Impact Vacuum status: On / Off 3-1-1-5 Power level No help text is available for this parameter.
Page 155 G3 series Description of menu Description of menu 3-2-5-2 Start emptying No help text available 4049 3-2-5-2 Stop emptying No help text available 4045 3-2-5-3 Mode No help text is available for this parameter. cool lubricate 4044 3-2-5-4 Pump level No help text is available for this parameter.
Page 156 Description of menu G3 series Description of menu Fig. 5-17 Squares (approx. 10 x 10 mm) distributed over the entire work surface 2269 3-3-3 Circle test cut Automatic initialisation with AKI Test running... For testing modules. Fig. 5-18 Circles (diameter approx. 10 mm) distributed over the entire work surface 2274 3-3-4 Diagonal test cut...
Page 157 G3 series Description of menu Description of menu Fig. 5-19 Diagonal over the entire work surface 2275 3-3-5 Random line Automatic initialisation with AKI Test running... Continuous load test Random lines distributed over the entire work surface 2276 3-3-6 Random curve Automatic initialisation with AKI Test running...
Page 158 Description of menu G3 series Description of menu Fig. 5-21 S test, 140 mm x 240 mm 2805 3-3-9 Move line Automatic initialisation with AKI Test running... as for diagonal test, except with limitation Define line ⇨ Move to starting point, choose OK to confirm ⇨...
Page 159 G3 series Description of menu Description of menu On: Module performs test Off: Module does not perform test 2670 3-3-18 Module 8 No help text is available for this parameter. Switch module 8 on/off On: Module performs test Off: Module does not perform test 2667 3-3-15 Module 5...
Page 160 Description of menu G3 series Description of menu No help text is available for this parameter. User 1 User 2 User 3 Operator Service Factory R&D Setting of which user level is automatically active once the cutter has been started Change password No help text is available for this menu.
Page 161 G3 series Description of menu Description of menu Communication setup Menu for the communication settings such as COM interface, parser etc. Communications settings for parsers, interfaces,... 2279 Serial interface No help text is available for this menu. Communication settings for the serial interfaces 2280 5-2-1 COM 1...
Page 162 Description of menu G3 series Description of menu HPGL port: 50000 3627 5-3-2 IP address No help text is available for this parameter. Display of the IP address. 3628 5-3-3 IP template No help text is available for this parameter. Display of the network template.
Page 163 G3 series Description of menu Description of menu Operating unit Menu for the panel-specific settings such as language, volume, contrast and the allocation of the function keys. All these settings are saved on the panel. If more than one panel is connected to a machine then each panel has its own settings. Settings for the operating unit 1590 Language...
Page 164 Description of menu G3 series Description of menu Fig. 5-22 Keyboard test Control segments of the travel keys Keyboard code Control segments of the operating keys ⇨ Press key ✓ the corresponding control segment of the keyboard test is highlighted and the key code is displayed Problem solution When pressing a key, the key code is not displayed or the corresponding control...
Page 165 G3 series Description of menu Description of menu System info settings No help text is available for this menu. Display of general information about the cutter 2311 Table type No help text is available for this parameter. G3_L2500 G3_M2500 G3_XL1600 G3_2XL1600 G3_3XL1600 G3_L3200...
Page 166 Description of menu G3 series Description of menu Maximum permitted E-box temperature 3186 X mot. temp. No help text is available for this parameter. Display of the temperature of the X drive motor 2523 8-10 Actual system outputs No help text is available for this menu. Current system outputs 1772 8-10-1...
Page 167: Troubleshooting
G3 series Malfunctions Troubleshooting Malfunctions Troubleshooting Attention! Risk of injury due to incorrectly remedied faults Ensure that the error on the device is remedied correctly. Contact you Zünd partner. If cutter malfunctions occur and you need the help of our customer service department, make a note of the following details: –...
Page 168 Malfunctions G3 series Locate error Error display on the status and error display (example) The error is displayed as a sequence. No redundant figures of the error code will be shown in this display. Example: The error 0x0001D503 is abbreviated to the figures 1D503. If several errors occurred one after the other then these are combined together in a group.
Page 169 G3 series Malfunctions Locate error 6.2.2 Error code The error code is made up of a 10-digit, uniquely allocated combination of numbers and letters. The signal word before the error code indicates how serious the error is. Signal Error Information Important information for the operator Caution Notification of possible problems (overheating).
Page 170: Error Messages
Malfunctions G3 series Error messages Error messages 0x00000603 Int err.No msg could be sent. Cmd: %0s Index: %1s No help available Contact service 0x00001303 An unknown parameter ID (0x%0s) was requested from the internal database. The parameter is not currently loaded or does not exist. No help available Contact service 3503...
Page 171 G3 series Malfunctions Error messages 0x00007702 Value outside of the validity range. Min = %0s Max = %1s Cause Parameter outside of the defined limits (HPGL). Solution Adjust parameter. 0x00007B04 HAL: Bit has already been assigned. HAL file row number: %0s No help available Contact service 0x00007C04...
Page 172 Malfunctions G3 series Error messages An error occurred when reading the frequency from the HAL file. The row is discarded. Contact service 0x00008B02 HAL: Error when reading a value. HAL file row number: %0s An error occurred when importing a value from the HAL file. The row is discarded. Contact service 0x00008C02 HAL: Error when reading a Boolean value.
Page 173 G3 series Malfunctions Error messages 0x0000A902 Incompl HP-GL comm Command %2s is incorrect. The HP-GL command has too few/too many parameters. Cause The HP-GL command was called up with too few parameters Solution Check HP-GL Manual for the call. AA02 Unknown XX command.
Page 174 Malfunctions G3 series Error messages Cause The sequencer must be in waiting status for the function which has been called up. Solution Wait until vectors have been processed. 0x0000D204 AD converter error. Index: %0s One or more axes cannot be controlled. Check connections. Contact service 0x0000D603 Error in the controller.
Page 175 G3 series Malfunctions Error messages 0x0000EE02 HAL: Error during the reading of the comm devices in the bus definition. HAL file row number: %0s An error occurred when reading the comm devices in the bus definition. There is probably an error in the HAL file. Contact service 0x0000EF02 HAL: Error during the reading of the device ID in the bus definition.
Page 176 Malfunctions G3 series Error messages 0x0000FB01 This user level requires a password. A password must be entered in order to enter the requested user level. Use the parameter password. The parameter editor is opened directly when you press information. Cause If the user level has been changed and a password is needed for this purpose then the entry of the password is displayed with this message.
Page 177 G3 series Malfunctions Error messages 0x00011E03 Incorrect key allocation to the axes. Change configuration or use new software ver- sion. Contact service 0x00011F02 The command may not be carried out in this operating status. Change the operating status in order to carry out the command. Cause The instruction was discarded because it is not permitted in the current instruction mode.
Page 178 Malfunctions G3 series Error messages 0x00012A03 This function is not permitted from this task. Command: %0s Caller index: %1s This is a programming error. Please inform the manufacturer. Contact service 0x00012B03 This initialisation mode is not supported. This is a programming error. Please inform the manufacturer. Contact service 0x00012C04 Axis inspection err.
Page 179 G3 series Malfunctions Error messages Solution Select the correct module or change the tool 14103 Z axis initialisation error. Axis: %0s Status: %1s No help available Contact Service 14203 T axis initialisation error. Status: %1s No help available Contact Service 0x00014403 Incorrect module active.
Page 180 Malfunctions G3 series Error messages Solution Select another port. 0x00015003 Tool timeout already active. Remove all tools from the modules and try again. Please inform the manufacturer. Contact service 0x00015102 No timeout job active. No timeout job active for this tool. Please inform the manufacturer. Contact service 0x00015201 Database successfully saved.
Page 181 G3 series Malfunctions Error messages 0x00015802 Incorrect parameter. Incorrect parameter for the HP-GL TR command. Cause Incorrect parameters were transferred when switching the tangential rotation on or off. Solution Correct the parameters. 0x00015901 The entire database was successfully reset to the default values. All database parameters of the currently loaded formula were reset to their default values.
Page 182 Malfunctions G3 series Error messages Contact service 0x00016901 No basic settings available. Set the table type and serial number. Contact service 0x00016A01 Different versions of the settings. Check settings and save. Contact service 0x00016B03 No HAL file found. No help available Contact service 0x00016C01 The database was empty during start-up.
Page 183 G3 series Malfunctions Error messages Solution Try another time. Contact the service department 0x00017402 Undefined status of an instruction. Programming error. Contact service 0x00017502 Error in the slide vacuum. No help available 0x00017704 Communication error on an internal bus (CAN). No help available Contact service 0x00017803...
Page 184 Malfunctions G3 series Error messages Cause The initialisation of a module was interrupted. The head modules are set to an uninitialised status and can no longer be moved. Solution The initial status can be reproduced by carrying out a reinitialisation of the head. When confirming the error, the head is reinitialised to module 1.
Page 185 G3 series Malfunctions Error messages Solution Authorise or move reference point 0x00018D03 Tool overcurrent. Overcurrent detected on the tool insert. Cause An overcurrent error occurred in the tool. Solution Pull the tool out of the material. 0x00018E03 Excess module temperature. The module insert has got too hot.
Page 186 Malfunctions G3 series Error messages No help available Contact service 0x00019904 Error during the system start-up. Restart the cutter. Error no.: %0s Error index: %1s Error during the initialisation of the axes. Contact service 0x00019A01 No travel movement is possible with the current module. A virtual module is active.
Page 187 G3 series Malfunctions Error messages Solution Check paging configuration. 0x0001A403 No material. No help available Contact service 0x0001A603 Incorrect number of parameters in the feed command. No help available Cause Incorrect number of parameters for a paging function. Solution Correct command 0x0001A703 HAL: Unknown Altera function.
Page 188 Malfunctions G3 series Error messages 0x0001AE02 Deletion failed. Tool is still assigned to a module. No help available Cause An attempt was made to delete a tool, but the tool is still connected to a module and therefore cannot be deleted. Solution The tool must first be removed from all modules.
Page 189 G3 series Malfunctions Error messages Cause A module was removed or added. In this process it was determined that the same zero point can no longer be used. 0x0001B702 Dummy module active. No help available Contact service 0x0001B801 Light barriers not active. No help available Contact service 0x0001B903...
Page 190 Malfunctions G3 series Error messages 0x0001C102 Cutter database is corrupt. The data has been lost. The standard values were used. No help available Contact service 0x0001C203 Automatic initialisation is not possible with this tool. Activate automatic initialisation tool on the tool or choose another tool. Cause The automatic initialisation tool cannot be used on this tool.
Page 191 G3 series Malfunctions Error messages Solution Position AKI in the park station. Restart cutter. 0x0001CA04 Errors occurred during the parameter transmission. Nothing has been saved. Restart the cutter in order to restore the old status. Errors occurred during the parameter transmission. The parameters which were transferred correctly have not yet been saved. The cutter must be restarted in order to restore the old status. Contact service 0x0001CB02 Automatic initialisation tool blocked for tool.
Page 192 Malfunctions G3 series Error messages Cause A module was assembled or dismantled without the system being notified. This can lead to a hazardous situation. 0x0001D402 ACBug Controller data lost. No help available Contact service 0x0001D503 Too many parameters selected for the ACBug output. No help available Contact service 0x0001D604...
Page 193 G3 series Malfunctions Error messages 0x0001DF04 The sequencer task has not started. The Altera is therefore not ready. No help available Contact service 0x0001E002 Unstable controller parameters. Axis: %0s Error:%1s i params 0x0001 neg high param 0x0002 pos low param 0x0004 high smaller than low v Params0x0100 0x0200...
Page 194 Malfunctions G3 series Error messages It was determined that the tool is not connected. The error occurs even when the error signals overcurrent and excess temperature are present when the tool is switched on. Contact service 0x0001ED03 Excess temperature of the X axis motor. No help available Cause An excessive temperature was measured on the X motor.
Page 195 G3 series Malfunctions Error messages Cause The vacuum generator has already been in use for more than 8000 h. Only a maximum of half the power is still available Solution Contact your service partner 0x0001F603 Callback functions could not be registered. No help available Contact service 0x0001F703...
Page 196 Malfunctions G3 series Error messages 0x00020102 Err. during data inspection. The data cannot be used. No help available Contact service 0x00020204 Err. during Altera programming. No help available Contact service 0x00020304 Short circuit detected. Index: %0s Index 0x01: Short circuit between 24 V and 24 V_NA. Contact service 0x00020403 Cam.
Page 197 G3 series Malfunctions Error messages Contact service 0x00021403 Rev transport with aux drive blocked. No help available 0x00021503 Trans file not a plotter update. No help available Contact service 0x00021603 Trans file not a panel update. No help available Contact service 0x00021703 Trans file not YM board update.
Page 198 Malfunctions G3 series Error messages 0x00022601 Changes to the Ethernet parameters will only become effective after the cutter is re- started. No help available 0x00022703 The received HPGL command does not correspond to the syntax: %2s No help available Contact Service 0x00022803 Universal board: Typing error.
Page 199 G3 series Malfunctions Error messages 0x00023301 OptionBoard (Str1A) not available. The external feed stop has therefore been deac- tivated. No help available Contact Service 0x00023403 The external feed stop is active. No help available Contact Service 0x00023703 The router converter is switched off. Switch it on using the standby key or via the router menu.
Page 200 Malfunctions G3 series Error messages Index 1: %0s Index 2: %1s No help available Contact Service 0x00024203 T-axis of the PUM is blocked. No help available Contact Service 0x00024403 Pilz emergency cables are crossed. No help available 0x00024504 Serious system error: %1s, %2s No help available 0x00024602 Please insert the MAM (marking module) into another slot...
Page 201 G3 series Malfunctions Error messages 0x00024E03 The gap between at least two measuring points was outside the tolerance. The measurements that are too low have been ignored. No help available 0x00024F03 The correction value measured is too high. No help available 0x00025003 A local elevation is outside the tolerance.
Page 202 Malfunctions G3 series Error messages No help available 0x00025C02 Axis inspection err. Axis %0s Error %1s An error occurred during the inspection of the axes. The motor or encoder may be incorrectly connected. Axis: Each half byte stands for an axis which may have an error. The corresponding error code stands for this axis.
Page 203 G3 series Malfunctions Error messages 0x00026603 The tool tip could not be clearly identified. Index: %0s No help available Restart initialisation. Contact Service if necessary. 0x00026702 The MAC address is set to default address. No help available Contact Service 0x00026803 External synchronisation unit %0s is not ready.
Page 204 Malfunctions G3 series Error messages 27503 Selection not permitted. No help available 6-38 000012,16,05-2010, jmu...
Page 205 G3 series Cleaning and maintenance General Cleaning and maintenance General – This chapter describes (in tabular form) all the maintenance jobs which are re- quired for the machine. – The maintenance list only affects the basic unit. Maintenance activities for mo- dules, tool inserts and options can be found in the respective operating manual.
Page 206 Cleaning and maintenance G3 series Safe maintenance of the machine Safe maintenance of the machine General safety instructions • Servicing and repair work must be carried out by trained specialist personnel. • For periodic checks/inspections you must comply with the mandatory intervals or the intervals specified in the instruction manual.
Page 207 G3 series Cleaning and maintenance Operating resources Operating resources 7.3.1 Handling operating materials Following the instructions for handling operating materials carefully will increase the reliability and service life of the machine. Follow the regulations for handling chemicals, particularly cleaning fluid and lubricants.
Page 208 Cleaning and maintenance G3 series Operating resources 7.3.2 Cleaning fluids Attention! The use of incorrect cleaning fluids not approved by Zünd will damage the machine. Only use cleaning fluids recommended by Zünd Systemtechnik. Do not use abrasive cleaning fluids. Caustic substances and scouring agents can damage surfaces of the cutter (e.g.
Page 209 G3 series Cleaning and maintenance Steps for maintenance Steps for maintenance Different types of symbols (circle, box, star – solid; circle, box, star – outline) divide the service and maintenance tasks into two groups. Meaning of symbols: Outline symbols: • This service and maintenance work is carried out by authorised service person- nel of Zünd Systemtechnik.
Page 210 Cleaning and maintenance G3 series Steps for maintenance Maintenance/inspection Work to be carried out during operating hours by personnel by authorised maintenance personnel one-off activity one-off activity repetitive interval repetitive interval when necessary when necessary General Visually check the machine for damage Free the machine of dust and processing residue Check electrical equipment (options) to ensure they function Check correct functioning of the emergency stop switch...
Page 211 G3 series Cleaning and maintenance Steps for maintenance Maintenance/inspection Work to be carried out during operating hours by personnel by authorised maintenance personnel one-off activity one-off activity repetitive interval repetitive interval when necessary when necessary Clean and oil the guide rails 7.7.7 Check alignment of toothed/steel belt and readjust if necessary Check tension of toothed/steel belt and readjust if necessary...
Page 212 Cleaning and maintenance G3 series Lubrication diagram Lubrication diagram Lubricate all lubricating points indicated in the lubrication diagram in accordance with the specified maintenance intervals. ® The machine is lubricated using Klüberoil 4UH1 Fig. 7-1 Lubricating points Place of lubrication Amount Cause Module carriage Right-hand bar guide...
Page 213 G3 series Cleaning and maintenance Accessories case Contents Accessories Amount Activity Allen screwdriver 4 x 170 mm Qty. 1 Assemble/disassemble modules Vacuum element spacers Qty. 6 Service/Installation Adhesive tape; width 19 mm Qty. 1 Service/Installation Teflon grease 20 ml Service Soldering fluid brush Qty.
Page 214 Cleaning and maintenance G3 series Maintenance jobs Maintenance jobs 7.7.1 Service flaps and covers Fig. 7-2 Service flaps, covers Item Description Task Cover Oil and clean the left-hand guide rails Cover Oil and clean the right-hand guide rails Cover Oil and clean the module carriage guide rails Maintenance unit access Drain the condensation water, set the pressure...
Page 215 G3 series Cleaning and maintenance Maintenance jobs 7.7.2 Maintenance position Warning! Danger of injury The cutter may be put into operation by third parties. • Always place the cutter in the maintenance position before carrying out mainte- nance work! Unless expressly required otherwise, move the machine to the maintenance position before starting maintenance work.
Page 216 Cleaning and maintenance G3 series Maintenance jobs 7.7.4 Clean the machine Zünd cutters are production machines that are subject to enormous amounts of stress on a daily basis. Keeping the machine clean will help to keep operation as free from interruption as possible. Important! Do not use compressed air to clean the machine.
Page 217 G3 series Cleaning and maintenance Maintenance jobs 7.7.5 Clean X axis guide rails Tools and materials Lubricant for guide rails, bearings Clean, lint-free rags 4 mm Allen key Ensure, that following precondition is fulfilled: ❏ The machine is in the maintenance position. Remove the covers Fig.
Page 218 Cleaning and maintenance G3 series Maintenance jobs Cleaning the guide rails Fig. 7-5 Oiling the guide rails ⇨ Push the bar forwards ⇨ Thoroughly clean the entire length of the guide rails using a lint-free rag ⇨ Soak a lint-free rag with lubricant for guide rails / bearings and oil the guide rails ⇨...
Page 219 G3 series Cleaning and maintenance Maintenance jobs 7.7.6 Oil X axis guide bearings Tools and materials Lubricant for guide rails, bearings Greasing set for X axis guide rails, bearings 4 mm Allen key Clean, lint-free rags Ensure, that following precondition is fulfilled: ❏...
Page 220 Cleaning and maintenance G3 series Maintenance jobs Guide bearings Fig. 7-7 Guide bearings The bar is mounted with 2 guide bearings on a guide rail on each side. Oil these bearings at intervals according to the maintenance schedule. 7-16 000001,10,11-2009, jmu...
Page 221 G3 series Cleaning and maintenance Maintenance jobs Lubricating the lubrication points Fig. 7-8 Lubricating the lubrication points ⇨ Push the bar forwards 7-17 000001,10,11-2009, jmu...
Page 222 Cleaning and maintenance G3 series Maintenance jobs ⇨ Screw the lubrication connection of the lubrication set onto the guide rails behind the bar (A, B) ⇨ Press the syringe until the feed line is ventilated ⇨ Position the guide bearings above the lubrication connection (C) ⇨...
Page 223 G3 series Cleaning and maintenance Maintenance jobs 7.7.7 Cleaning/oiling Y axis guide rails Tools and materials Lubricant for guide rails, bearings 4 mm Allen key Clean, lint-free rags Ensure, that following preconditions are fulfilled: ❏ The machine is in the maintenance position. ❏...
Page 224 Cleaning and maintenance G3 series Maintenance jobs Cleaning the guide rails Fig. 7-10 Cleaning the guide rails ⇨ Clean the entire length of the guide rails using a lint-free rag ⇨ Soak a lint-free rag with lubricant for guide rails / bearings and oil the guide rails ⇨...
Page 225 G3 series Cleaning and maintenance Maintenance jobs 7.7.8 Lubricating the Y axis bearing Tools and materials Lubricant for guideways 4 mm Allen key Clean, lint-free rags Cardboard base or drip tray Ensure, that following preconditions are fulfilled: ❏ The machine is in the maintenance position. ❏...
Page 226 Cleaning and maintenance G3 series Maintenance jobs 7.7.9 Clean the chipping protection brush Ensure, that following precondition is fulfilled: ❏ The machine is in the maintenance position. Cleaning the brush Fig. 7-12 Clean the chipping protection brush ⇨ Use a vacuum clean to extract chips and dust from the brushes 7-22 000001,10,11-2009, jmu...
Page 227 G3 series Cleaning and maintenance Maintenance jobs 7.7.10 Cleaning the feeding clamps/feed guide rail Tools and materials Lint-free cloth Spirit Ensure, that following precondition is fulfilled: ❏ The machine is in the maintenance position. Procedure Fig. 7-13 Cleaning the feeding clamps/feed guide rail ⇨...
Page 228 Cleaning and maintenance G3 series Maintenance jobs 7.7.11 Draining the maintenance unit condensation water Tools and materials Container Ensure, that following precondition is fulfilled: ❏ The machine is switched off. Procedure Fig. 7-14 Drain condensation water Disposal! ⇨ The condensation liquid from the water separator is contaminated with oil. Therefore the liquid must be disposed of correctly according to the specific national regulations.
Page 229 G3 series Cleaning and maintenance Maintenance jobs 7.7.12 Automatic circuit breakers Attention! Danger of injury by electric shock Hazardous voltage in the power unit • Do not remove the power box cover under any circumstances. • Contact your service partner if you have any problems with the energy supply. Attention! Danger of machine damage If an automatic circuit breaker has been triggered then there is an electrical defect in...
Page 230 Cleaning and maintenance G3 series Maintenance jobs Automatic circuit breakers Fig. 7-16 Automatic circuit breakers Fuse Consumer Cutter control, compressor, PC Vacuum cleaner, various options Auxiliary drive, router converter Important! Maximum current: 16 A/phase 7-26 000001,10,11-2009, jmu...
Page 231 G3 series Cleaning and maintenance Maintenance jobs 7.7.13 Conveyor belt Tools and materials Conveyor belt Stapler with suitable staples (6 mm) Applicator gun 2 component adhesive (cartridge) Spatula Masking tape (2 cm wide) Gaffer tape Industrial scissors Ensure, that following precondition is fulfilled: ❏...
Page 232 Cleaning and maintenance G3 series Maintenance jobs Removing the conveyor belt ⇨ Cut the conveyor belt using scissors and remove it. ⇨ Dispose of the conveyor belt correctly. 7.7.13.2 Removing the covers Fig. 7-18 Removing the covers ⇨ Lift the covers (1 x front, 1 x rear) and remove from the guide. 7-28 000001,10,11-2009, jmu...
Page 233 G3 series Cleaning and maintenance Maintenance jobs 7.7.13.3 Fitting a conveyor belt Important! Conveyor belt installation is dependent on the direction of movement. Pay attention to the marks on the belt and ensure that the belt is fitted correctly. Determining conveyor direction Fig.
Page 234 Cleaning and maintenance G3 series Maintenance jobs Front CE (CE2500 and CE3200) Front CE (CE0800, CE1250 and CE1600) 7-30 000001,10,11-2009, jmu...
Page 235 G3 series Cleaning and maintenance Maintenance jobs Front CE (CE0800, CE1250 and CE1600) and rear CE (CE2500 and CE3200) Front CE (CE0800, CE1250 and CE1600) and rear CE (CE0800, CE1250 and CE1600) 1 Conveyor belt guides 3 Guide rollers on the feet 2 Guide rollers Important! ⇨...
Page 236 Cleaning and maintenance G3 series Maintenance jobs Gluing the conveyor belt Attention! Toxic fumes • Do not breath in glue fumes. • Only use glue in well ventilated rooms. Attention! Skin bonding or being irritated by glue • Do not allow glue to come into contact with skin. •...
Page 237 G3 series Cleaning and maintenance Maintenance jobs Fig. 7-21 Gluing the conveyor belt 7-33 000001,10,11-2009, jmu...
Page 238 Cleaning and maintenance G3 series Maintenance jobs 1 Assembly base 5 Masking tape, layer 1 2 Adhesive tape 6 Masking tape, layer 2 3 Conveyor belt 7 Applicator gun with 2-component glue 4 Stapler 8 Spatula ⇨ Set up the conveyor belt straight and fix in place with adhesive tape. If necessary, turn on the vacuum to prevent the conveyor belt slipping.
Page 239 G3 series Cleaning and maintenance Maintenance jobs Tensioning the conveyor belt Fig. 7-23 Tensioning the conveyor belt 1 Left/right tensioning screws ⇨ Tighten tensioning screws. ✓ The conveyor belt is tensioned. ⇨ Repeat the procedure on the other side. Aligning the conveyor belt run 1-7-1-2 ⇨...
Page 240 Cleaning and maintenance G3 series Instructions for disposal Instructions for disposal Important! Contact Zünd customer services or your service partner before you dispose of your cutter. Zünd cutters are modern industrial devices which correspond with the current standards and guidelines on the disposal of old appliances. •...
Page 241 G3 series Tools Tools 000005,04,06-2009, jmu...
Page 242 Tools G3 series 000005,04,06-2009, jmu...
Page 243 G3 series Modules Modules 000004,04,06-2009, jmu...
Page 244 Modules G3 series 000004,04,06-2009, jmu...
Page 245 G3 series Options 10 Options 10-1 000007,04,06-2009, jmu...
Page 246 Options G3 series 10-2 000007,04,06-2009, jmu...
Page 247 G3 series Material handling 11 Material handling 11-1 000006,04,06-2009, jmu...
Page 248 Material handling G3 series 11-2 000006,04,06-2009, jmu...
Page 249 G3 series Additional specifications 12 Additional specifications 12-1 000008,04,06-2009, jmu...
Page 250 Additional specifications G3 series 12-2 000008,04,06-2009, jmu...
Page 251 G3 series Documents 13 Documents 13-1 000029,03,06-2009, jmu...
Page 252 Documents G3 series 13-2 000029,03,06-2009, jmu...
Page 253 G3 series Glossary 14 Glossary User level The menu has a hierarchical division into user levels. Each user level can be activated by entering a password. Operating status ONLINE Jobs are processed in this operating status. Operating status OFFLINE In this operating status, data are received but not processed. In this operating status it is possible to use remote controlled commands to switch to the operating status ONLINE.
Page 254 Glossary G3 series Menu number The menu is numbered consecutively and hierarchically. Modules Modules serve as the interface between the cutter and the tool. Emergency stop Emergency stop switches are safety elements which cause the immediate switching off of the machine in hazardous situations Numerical keys Keys for making numerical entries on the operating unit.

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Zund M-1600 Operating Manual

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Summary of Contents for Zund M-1600

Page 19: Intended Use

Page 49: Safety Signs

Page 167: Troubleshooting

Page 170: Error Messages

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