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Gerber Dimension 200 Manual

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Introduction

The Dimension 200 is a router/engraver for three-dimensional
signage created for use with the GRAPHIX ADVANTAGE or
other computer systems along with ART Path software.
The ART Path Software Option allows the GRAPHIX
ADVANTAGE to fully control the routing operation, enabling
you to send jobs directly from ART Path on the GRAPHIX
ADVANTAGE through the ADVANTAGE Router Control
(ARC) station.
The Dimension 200 can cut designs from a variety of materials, as
well as draw all types of text or graphics. In addition, the
Dimension 200 is an excellent solution for creating ADA-
compliant (Americans with Disabilities Act) signage.
Warning: THE DIMENSION 200 IS A COMPUTER-
CONTROLLED MACHINE TOOL AND SHOULD BE
OPERATED ONLY BY TRAINED OPERATORS. THE SAFETY
GUIDELINES IN THIS MANUAL MUST BE FOLLOWED AT
ALL TIMES TO AVOID RISK OF INJURY.

Manual Contents

This manual provides installation, operation, and maintenance
procedures as well as safety guidelines for the Dimension 200.
Covering the basic information needed for using the Dimension
200, it is arranged as follows:
Router requirements and package contents
Stand assembly instructions
Router and optional equipment installation instructions
Safety guidelines
Principles of operation
System preparation and use
1

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Summary of Contents for Gerber Dimension 200

  • Page 1: Introduction

    ADVANTAGE through the ADVANTAGE Router Control (ARC) station. The Dimension 200 can cut designs from a variety of materials, as well as draw all types of text or graphics. In addition, the Dimension 200 is an excellent solution for creating ADA- compliant (Americans with Disabilities Act) signage.

  • Page 2: Conventions

    Customer Support If you require assistance installing or operating your Dimension 200, contact your Gerber distributor or the Router Support Group at 800-336-1698 (USA and Canada) or fax at 203-290-5568. If possible, please use a phone that is close to your GRAPHIX...

  • Page 3: Router Requirements

    300 lbs. ELECTRICAL BOX Gerber recommends placing the electrical box on the table beside the unit or under the table. The power switch must be easily accessible. Do not set the box directly on concrete floors because of condensation potential.

  • Page 4: High Frequency Spindle Option And Speed Controller

    Gerber distributor. Electrical Requirements The Dimension 200 has specific power requirements which must be supplied for the system to work properly. Gerber recommends that all power requirements be installed by a licensed industrial electrician.
  • Page 5 Router Requirements Requirements are as follows: Electrical Box: Domestic systems: 200, 208, 220, 230, or 250V AC, 30 amp, 60 Hz, single phase, dedicated line. NEMA Reference 3-POLE, 4-WIRE Receptacle: L14-30R Plug: L14-30P Neutral Export systems: 200, 208, 220, 230, or 250V AC, 20 amp, 50 Hz, single phase, dedicated line.
  • Page 6 Dimension 200 Speed Controller: 200-240V AC ±10%, 20 amp, 50/60 Hz, single phase, dedicated line. NEMA Reference 2-POLE, 3-WIRE Receptacle: 6-15R Plug: 6-15P GROUND Note: If the High Frequency Spindle Option is purchased, a licensed industrial electrician must install a dedicated power line for the Speed...

  • Page 7: Router Package Contents

    Router Requirements Router Package Contents Contents of the large shipping crate for the Dimension 200 are listed below. Check each part against the list and inspect all parts for any damage which may have occurred during shipping. : Do not attempt to assemble and install the WARNING Dimension 200 without adequate assistance.
  • Page 8 Dimension 200 Small Components Box: ARC station power supply Ground strap with connectors and instructions Power cord for the ARC station power supply 100' 9-pin to 25-pin RS-232 cable 8' 37-pin cable Owner's Guide Warranty Stand Kit: Legs Front/Rear Cross Members...

  • Page 9: Tool Kit Contents

    Collet wrench set Collet nut .250" collet (6 mm) .125" router bit sleeve (3 mm) .500" collet .125" Gerber Gold bits (3 mm) .250" Gerber Gold bits (6 mm) .020" profile cutter (engraver type) (6 mm) Table surfacing bit Pen assembly...
  • Page 10 Dimension 200 Note: The contents of your tool kit may vary from the photograph.

  • Page 11: Router Stand Assembly

    PERSONS TO LIFT THE ROUTER TABLE BECAUSE OF ITS WEIGHT. CAUTION: When removing the four foot subassemblies from the Dimension 200 router table, do not set the table on the ground. Damage to the undercarriage will occur. Use the wooden packing materials to block up the router table.
  • Page 12 Dimension 200 LEG ASSEMBLY...

  • Page 13: Assemble The Stand

    Router Stand Assembly Assemble the Stand 1. Attach the front, side, and rear cross members to the legs (as shown in the Assembled Stand figure) using the specified parts. Do not yet tighten the nuts. 2. Attach the front, side, and rear tie members to the legs (as shown in the Assembled Stand figure) using the specified parts.
  • Page 14 Dimension 200 ASSEMBLED STAND 2. To lower a foot subassembly, use a 13 mm wrench to loosen the top nut inside the leg frame. When the foot is lowered sufficiently, tighten the bottom nut against the bottom of the leg frame.

  • Page 15: Router Installation Procedure

    Router Installation Procedure Before You Begin WARNING: Turn OFF power to the GRAPHIX ADVANTAGE and unplug the system from the outlet. DO NOT plug in power until instructed to do so. WARNING: Turn OFF and unplug any lettering systems or plotters connected to the GRAPHIX ADVANTAGE.

  • Page 16: Connect Power Supply To Arc Station

    Dimension 200 ARC Station Connect Power Supply to ARC Station 1. Plug the single-pronged end of the ARC station power cord into the port labeled R831 on the ARC station (the other end already connects to the power supply box). See the above illustration.

  • Page 17: Connect Electrical Box To Router Table

    Router Installation Procedure Connect Electrical Box to Router Table 1. Plug the 3-pronged power cord from the router table into the receptacle labeled R849 on the electrical box. 2. Connect the cable labeled P856 (X motor cable bundled with the Y and Z motor cables on the router table) to the receptacle labeled R856X.

  • Page 18: Connect Chip Removal System

    A heavy duty wet/dry shop vacuum is required and is not supplied with the router system. A 2 1/2" (64 mm) diameter hose and all necessary fittings are provided with the Dimension 200. INSTALLING THE CHIP REMOVAL SYSTEM WARNING: BEFORE INSTALLING THE CHIP REMOVAL SYSTEM, UNPLUG THE ELECTRICAL BOX FROM ITS POWER SOURCE.
  • Page 19 To attach the vacuum hose 1. Attach the vacuum hose onto the pressure foot of the Dimension 200. (One end of the ground strap cable is already connected at this end in the interior of the hose.) 2. Lead the vacuum hose and the ground strap which extends from the end of the vacuum hose to the electrical box.

  • Page 20: Connect The Ground Strap Cables

    To connect the ground strap cable at the router table 1. At the left rear of the Dimension 200 router table, remove the left capscrew that secures the foot mount block to the router bed.
  • Page 21 (triangle with an exclamation point). 2. Insert the removed screw through the ring lug of all three ground strap cables (from the Dimension 200 router table, the ARC station, and the vacuum shroud). 3. Place one star washer over the screw.

  • Page 22: Connect Graphix Advantage To Arc Station

    Dimension 200 Connect GRAPHIX ADVANTAGE to ARC Station 1. Plug the 9-pin D-connector of the RS-232 cable into the port labeled at the rear of the GRAPHIX PLOTTER ADVANTAGE. Carefully align all pins and press all the way 2. Tighten the connector thumb screws to secure the cable to the system.

  • Page 23: Set Up The Arc Station

    The ARC station can support several different routers. When you first install your system, follow the procedure below to configure the ARC station for the Dimension 200. (See page 39 for an illustration of the front panel of the ARC station.) 1.
  • Page 24 Dimension 200 Below is an illustration of the basic Dimension 200 system and its peripherals to assist you in installing and checking the connections. The illustration does not depict the actual connections or placement of the equipment.

  • Page 25: Optional Equipment Installation

    The Mist Coolant System requires 30-100 psi of compressed air. The compressor is purchased separately. The Mist Coolant System is designed to be used with Gerber Cool coolant, a high performance spray lubricant available from Gerber Scientific Products, Inc. Gerber Cool is a non-toxic, biodegradable coolant custom-formulated for Gerber routers.

  • Page 26: Installing The Mist Coolant System

    Dimension 200 from the AC outlet before installing the Mist Coolant System to avoid possible electrical shock. 1. Remove the top two screws from the Dimension 200 right end plate on the right end of the beam when viewed from the front.
  • Page 27 Optional Equipment Installation side of the carriage when viewed from the front. See the illustration at right.
  • Page 28 Dimension 200 The illustration below shows the Dimension 200 carriage with the optional High Frequency Spindle Motor installed (on the upper left) and Mist Coolant Option components (on the lower right).

  • Page 29: T-Vac Vacuum System

    12. Insert the quick-disconnect fitting to the opposite end of the air line and connect to the compressor. 13. Turn on the Dimension 200. Make sure the coolant hose travels smoothly in the cable trough by slewing the carriage from one end of the beam to the other. The coolant hose must not stretch as the carriage moves.
  • Page 30 Dimension 200 3. Insert the 2" diameter hose supplied in the kit on the intake opening on the table and secure with a hose clamp. 4. Insert the 2" adapters supplied in the kit on the reducing tee as shown above.

  • Page 31: Speed Controller System

    Optional Equipment Installation 10. Attach the other end of the hose to the vacuum blower with a 2" barb adapter, cutting the hose as short as possible to increase the efficiency of the blower. Secure with a hose clamp. 11. Have a licensed industrial electrician with industrial motor experience wire the vacuum blower.

  • Page 32: Using The Speed Controller System

    Dimension 200 USING THE SPEED CONTROLLER SYSTEM The Speed Controller System is used to control the spindle speed of the High Frequency Spindle motor. The thickness and type of material, as well as the tool selected, determine the correct spindle speed.

  • Page 33: Engraver Vacuum System Option

    Optional Equipment Installation Engraver Vacuum System Option The optional Engraver Vacuum System is a quiet, conveniently- sized system used to clean debris from the table and engraving area. To assemble the Engraver Vacuum System 1. Remove and discard the plugs from the holes labeled IN and OUT on the front of the vacuum motor.

  • Page 35: Safety Guidelines

    Safety Guidelines Warning: THE DIMENSION 200 IS A HIGH-SPEED CUTTING MACHINE. ITS USE MAY BE HAZARDOUS IF YOU DO NOT OBSERVE THE FOLLOWING PRECAUTIONS. THESE GUIDELINES ARE NECESSARY FOR THE SAFE AND EFFICIENT OPERATION OF THE DIMENSION 200. WARNING: DO NOT STORE WET ALUMINUM CHIPS IN A CLOSED CONTAINER AND DO NOT USE THE VACUUM HOSE TO CLEAN UP WET ALUMINUM.
  • Page 36 Dimension 200 10. Remove loose jewelry, ties, and loose clothing. Wearing a long-sleeved shop coat is strongly recommended. 11. Wear ear protection. 12. Keep all personnel at a safe distance from the machine when it is operating. 13. Carefully secure the workpiece with clamps.

  • Page 37: Operating Principles

    Operating Principles Overview Note: It is essential that you read this section before operating the Dimension 200. This section introduces the operating principles of the router system. The complete Dimension 200 router system consists of these major components: the Dimension 200 router table...

  • Page 38: Z Axis

    The Z axis of the router is the up and down movement of the tool. Initializing the Z axis is an essential procedure when using the Dimension 200. It establishes the location of the tool above the workpiece at the start of a job.

  • Page 39: Job Home Position

    Operating Principles Job Home Position The job home position is the position on the router table which corresponds to the job 0,0 point or starting position of the job. The job home position is stored in the ARC station and is maintained even when power is interrupted.

  • Page 40: Power Switch

    Dimension 200 Power Switch The main power switch is located on the front of the electrical box, encircled by a yellow border. It switches power on and off at the ARC station. Turn the power on or off here for normal use.

  • Page 41: Arc Station

    Operating Principles ARC Station The Advantage Router Control (ARC) station is the communication link between the GRAPHIX ADVANTAGE and the router system. It can do the following: send and receive messages and commands to and from the GRAPHIX ADVANTAGE display messages to the operator control router motor movements change feed rates return the router carriage to the job home position...

  • Page 42: Front Panel

    Dimension 200 FRONT PANEL The front panel of the ARC station consists of a message display panel and nine function keys: START/STOP RESET Z INIT SELECT right, left, up, and down arrow keys. The ENTER key is not used. Display Panel...

  • Page 43: Power-Up Tests

    Operating Principles Power-Up Tests When the power is turned ON, the ARC station performs diagnostic self-tests, and displays the operating set revision level. The ARC station requests the operator to slew the router carriage near the point of orientation, which is the absolute 0,0 point. To slew to the point of orientation, use the arrow keys to move the router carriage as far toward the front and to the left as possible.

  • Page 44: Function Keys

    ARC station after a selection has been made in the Menu Select mode. See the page in this section on Menu Select mode. To slew the Dimension 200 To position the tool to the left or right over the router table surface, press the left or right arrow keys until the desired placement is reached.

  • Page 45: Start/Stop

    2. Press the START/STOP key to display the START READY message. The Dimension 200 is now in a “ready” state and the message remains until the data arrives from the GRAPHIX ADVANTAGE. The current tool position becomes the start point for the job.
  • Page 46 When the job data is received, the message appears, START JOB indicating that the Dimension 200 is in a “run” state. ART Path sends a header or tool message, the system goes into STOP JOB mode and instructs the operator to load material. Press START/STOP again to display the tool assignment.
  • Page 47 Operating Principles Stop Ready In STOP READY, the GRAPHIX ADVANTAGE sends data to the ARC station. The system beeps when data is received and J, j is displayed in the lower right corner of the message display panel. Press the START/STOP key to begin the job. The carriage can be slewed to establish a start position for the next job.
  • Page 48 Dimension 200 Resume Processing After pausing temporarily, press the START key to resume processing without position or data loss. Change Tools If a tool change is required, follow the steps below: 1. In STOP JOB mode, slew the carriage to a safe tool change position.
  • Page 49 Operating Principles Repeat Job To repeat a job at the same position as the previous job, before pressing START/STOP: 1. Press SELECT while in the STOP READY mode to access the Menu Select mode. 2. Press the right or left arrow key until appears RETURN HOME in the message box.

  • Page 50: Reset

    Dimension 200 RESET The RESET function key immediately halts the job that is running. In Start Mode If in START JOB mode and the operator presses the RESET key: the tool raises the carriage X,Y travel stops current job data from the router and the GRAPHIX ADVANTAGE clears message displays.

  • Page 51: Z Init

    Operating Principles Z INIT The Z INIT function key initializes the Z axis tool height above the work surface. The Z INIT key may be used only when the message displays. You may use either STOP JOB STOP READY the tool height gage or the step height gage for initialization. CAUTION: The Z axis must be set every time the tool or material is changed.

  • Page 52: Enter

    Dimension 200 ENTER This function key is not used in this release. Press SELECT to exit a selection and store values. Press RESET to exit a selection without storing values. SELECT This function key allows access to the Menu Select mode to set system parameter values.

  • Page 53: Using Select

    Operating Principles Using Select To access the Menu Select mode, press SELECT while in the STOP READY or STOP JOB mode. The choices available are as follows: Absolute (X,Y): Set Job Home Return Home Feed Rate: Motor Delay: Test: Display: Default Note: A colon (:) following a menu selection indicates additional choices are available when the item is selected.

  • Page 54: Absolute X,Y

    Dimension 200 ABSOLUTE X,Y: The Absolute X,Y function displays the exact position of the router tool relative to the absolute 0,0 position on the router table established during orientation when the router was turned on. The Absolute X,Y display allows the operator to position the router tool with great precision and helps set the job home position.

  • Page 55: Set Job Home

    Operating Principles SET JOB HOME The job home position is the point that corresponds to the starting point of the job. It is the point by which a job is positioned on the router table. ART Path considers the current tool position to be job home.
  • Page 56 Dimension 200 WARNING: Do not use the Set Job Home parameter to reset home after cutting has begun. The carriage will move unpredictably when the job is restarted. To set job home 1. Slew the carriage to the desired job home position by pressing the arrow keys.
  • Page 57 Operating Principles To display current job home 1. To avoid hitting clamps, slew the carriage near the home position using the arrow keys. 2. Press SELECT while in the STOP READY or STOP JOB mode. 3. Press the right or left arrow key until appears RETURN HOME in the message box.

  • Page 58: Job Home Position And Job Boundaries

    JOB HOME POSITION AND JOB BOUNDARIES Job boundaries cannot exceed the active cutting area of the router table. The Dimension 200 and ART Path interpret job boundaries for certain job types in these ways: Output repeats are considered to include all repeats within the job boundary.

  • Page 59: Return Home

    Operating Principles RETURN HOME The Return Home feature allows the operator to return the carriage to the last Job Home position. The Job Home position is stored when a job is started or when the Set Job Home function is used.
  • Page 60 Dimension 200 To change feed rate CAUTION: The feed rate override is not cleared after the job completes and will be applied to the next job received. 1. Press SELECT while in the STOP READY or STOP JOB mode. 2. Press the right or left arrow key until Feed Rate: appears in the message box.

  • Page 61: Motor Delay

    The Motor Delay parameter sets the time the tool will wait for the router to reach full speed before it descends to the material. Valid values are 0 to 99 seconds. Gerber recommends a setting of 05 (five seconds). To change motor delay 1.

  • Page 62: Display

    Dimension 200 DISPLAY: This function allows you to set the language and units which display in the ARC station message box. It also allows you to turn Auto Scroll on or off. When on, Auto Scroll automatically scrolls messages that are too long to fit in the message box.

  • Page 63: Default

    Operating Principles 5. Press the right or left arrow key to scroll through the units choices (inches or millimeters). Units: Inches 6. Press SELECT to save the selected choice. The system beeps twice and returns to the STOP READY or STOP JOB mode displayed.

  • Page 65: System Preparation And Use

    System Preparation and Use This section discusses the procedures to follow before and during the operation of the Dimension 200: Preliminary preparation Router motor installation/removal Tool selection, installation, removal, and replacement Table mat milling and engraving Material selection and preparation...

  • Page 66: Preliminary Preparation

    3. Raise the router motor by manually turning the Z axis adjustment knob, located on top of the Z axis motor. 4. Adjust the feet of the Dimension 200 to a higher or lower position to ensure that the router table is level.

  • Page 67: Router Motor Installation/Removal

    System Preparation and Use Router Motor Installation/Removal For your convenience, the Dimension 200 is shipped with the router motor already installed. However, should a problem occur requiring the motor to be removed, please follow the instructions below. To remove the router motor 1.
  • Page 68 Dimension 200 4. Tighten the screws on the collar of the motor mount and plug in the router motor cord into the outlet on the router. Note: The photograph below is for illustration purposes only and may vary somewhat from your router motor.

  • Page 69: Tool Selection

    Tool Selection PEN TOOLS When first using the Dimension 200, be sure to learn as many system functions as possible with the pen tool. Do not try to cut material with the router until you have mastered the basic system functions using the pen.

  • Page 70: Collets

    If larger bits are purchased, scale the limitations proportionally for larger cutters. Gerber sells a complete line of high quality cutting tools that provide optimum cutting performance. Contact your Distributor for details.

  • Page 71: Tool Installation

    System Preparation and Use TOOL INSTALLATION Solid carbide tools, such as those included in the tool kit, must be handled very carefully. caution: DO NOT STRIKE THE CUTTING EDGE WITH THE COLLET OR ADAPTER DURING TOOL INSTALLATION. To install the tool 1.
  • Page 72 Dimension 200 6. Be sure that the collet and spindle are clean and undamaged.

  • Page 73: Tool Removal

    System Preparation and Use 7. Insert both the tool and collet into the opening at the base of the router motor, as shown below. 8. Hold the collet to prevent the tool from falling out and hand tighten the retaining nut. 9.

  • Page 74: Pen Tool Replacement

    Dimension 200. Gerber is not responsible for results obtained with cutters not recommended in this manual or purchased from other dealers. Be sure to get only the highest quality cutters for use with the...

  • Page 75: Mat Milling

    System Preparation and Use Table Mats The Dimension 200 table mats provide accurate depth control and minimize the need for sacrificial material. They are installed at the factory but are milled on-site after installation to provide a perfectly flat surface.

  • Page 76: Grid Engraving

    Dimension 200 10. Using the arrow keys, move the carriage to the extreme lower left corner (absolute 0,0 or the orientation point) of the table. 11. In ART Path, click on Output. The Job Output dialog box appears. (Make sure that no pre-position moves have been entered.)
  • Page 77 System Preparation and Use The number data is supplied in the file GRIDNUMB.RTP GRIDNUMB.RTP To engrave the grid 1. In ART Path, choose Open from the File menu. 2. Highlight Router Files under List Files of Type to open . Click on OK. ENGRGRID.RTP 3.
  • Page 78 Dimension 200 11. In ART Path, click on Output. The Job Output dialog box appears. (Make sure that no pre-position moves have been entered.) 12. Click on Rout. 13. Press START/STOP three times to begin grid milling. This displays the header and tool messages and begins routing.

  • Page 79: Grid Engraving With T-Vac Option

    System Preparation and Use 12. Press START/STOP three times to begin table milling. This displays the header and tool messages and begins routing. GRID ENGRAVING WITH T-VAC OPTION The grid engraving program is supplied with ART Path in the file. The file contains a similar grid VACGRID.RTP VACGRIDM.RTP...

  • Page 80: Material Selection And Preparation

    13. Press START/STOP three times to begin the grid. This displays the header and tool messages and begins routing. Material Selection and Preparation The Dimension 200 can draw on any kind of material suitable for a ballpoint pen, and cut virtually any routable material including those listed below.

  • Page 81: Choosing Sacrificial Material

    System Preparation and Use Because different routable materials have different densities, varying cutting speeds are required. A table of recommended cutting speeds for various materials is included at the back of this manual. CHOOSING SACRIFICIAL MATERIAL You may place a piece of sacrificial material under the workpiece when cutting.
  • Page 82 Dimension 200 especially suitable for securing metals which produce high cutting forces. High Tack Tape is available through Gerber or most industrial and office supply distributors. Note: Using both tape and spray adhesive is a good alternative on rough-textured wood.

  • Page 83: Using Tape

    System Preparation and Use USING TAPE Follow these guidelines when using tape to attach the workpiece to the table mats: Place the tape in closely spaced strips. Do not overlap the strips. Make sure the centers of letters like O, B, and P are held securely by the tape.

  • Page 84: Mounting The Workpiece

    Dimension 200 CAUTION: Spray adhesive is sticky. Do not spray near the router table. To attach the workpiece to the sacrificial material 1. Spray the adhesive in smooth, even strokes across the back of the workpiece. 2. Coat the entire surface uniformly, including edges and corners, until tacky, but not wet.
  • Page 85 System Preparation and Use If the workpiece is thick, use a clamp block (shim) of equal thickness under the free end of the work clamp to keep the clamp level and maximize its holding ability. CAUTION: When moving the router motor with the slew keys, or during router operation, take care not to run the vacuum shroud into the work clamps.

  • Page 86: Using T-Vac Vacuum Hold-Down

    Dimension 200 USING T-VAC VACUUM HOLD-DOWN The T-Vac Vacuum System reduces the need for adhesives and sacrificial materials because it holds the workpiece securely on the table without adhesives. With certain materials, you may wish to use sacrificial material. T-Vac is not recommended for use with very small workpieces, very thick or porous materials, or materials with irregular surfaces.

  • Page 87: Using Both Clamps And T-Vac

    System Preparation and Use When using T-Vac vacuum hold-down, follow these guidelines: The workpiece must be flat. Do not use T-Vac with porous materials, very thick materials, or materials with irregular surfaces. The workpiece must cover most of the vacuum holes. Up to 30 holes may be uncovered at the start of the job.

  • Page 88: Pressure Foot And Pressure Foot Pad

    Dimension 200 PRESSURE FOOT AND PRESSURE FOOT PAD The Chip Removal System includes a pressure foot to hold material flat against the router table to prevent it from lifting while routing. The pressure foot also makes the router safer by preventing chips and small pieces of material from being thrown out of the machine while routing.
  • Page 89 System Preparation and Use To replace the pressure foot pad 1. Align the pad screw holes with the holes on the pressure foot. 2. Replace the screws and tighten just enough to compress the cushion slightly. A thread locking compound should be used. Loctite...

  • Page 90: Using The Mist Coolant System

    Dimension 200 Using the Mist Coolant System CAUTION: The Mist Coolant System has been designed to be used with Gerber Cool coolant. DO NOT dilute Gerber Cool prior to use. CAUTION: Use of other types of fluids may damage the system.

  • Page 91: Using The Step Height Gage

    Using the Step Height Gage The step height gage enhances the depth accuracy of the Dimension 200. When working with a milled table surface, you can set the depth of cut so precisely that masked materials, such as acrylic sheet, can be cut while leaving the bottom layer of masking paper intact.

  • Page 92: Unlock And Initialize The Z Axis

    Dimension 200 UNLOCK AND INITIALIZE THE Z AXIS 1. Place the step height gage on the milled table surface next to the workpiece to be cut. Ensure that the table surface is clean. Note: Debris under the gage will cause inaccurate measurement and poor results.

  • Page 93: Depth Of Cut

    System Preparation and Use DEPTH OF CUT Set the depth of cut in ART Path to the decimal equivalent of the step height selected on the step height gage. This will leave the bottom mask layer intact. Decimal equivalents of step heights are shown below.

  • Page 95: Cleaning And Maintenance

    Cleaning and Maintenance The Dimension 200 is relatively simple to operate and easily maintained. However, routine checking and cleaning of the equipment can significantly reduce the likelihood of major problems. Router maintenance is based on daily inspection of the equipment and daily and weekly cleaning procedures.

  • Page 96: Daily Inspection

    Dimension 200 Daily Inspection Component What To Check For Entire machine surface Chip buildup, mist coolant buildup, table slot debris X and Y ways Debris buildup Lead screws Debris buildup Router carriage, linear Debris buildup bearing seals Mist coolant nozzle...

  • Page 97: Twice Weekly Cleaning

    Cleaning and Maintenance TWICE WEEKLY CLEANING Clean the T-Vac air filter twice a week or even more frequently if there is heavy use. Debris buildup in the filter will reduce vacuum hold-down and may cause the vacuum to overheat and fail. SUPPLIES The following tools and supplies are recommended for the cleaning procedures:...

  • Page 98: Y Axis Ways

    Dimension 200 X AXIS WAYS The X axis ways are the shafts located on the beam on which the router motor carriage moves. To clean the X axis ways 1. Locate the two X axis ways. 2. Clean the X axis ways by wiping them with a lint-free cloth.

  • Page 99: Lead Screws

    Cleaning and Maintenance LEAD SCREWS The lead screws are located along the width of the router motor carriage below the ways, on the Z axis, and beneath the center front of the router. (See the previous photograph and illustration.) CAUTION: DO NOT OIL THE LEAD SCREWS. 1.

  • Page 100: Weekly Inspection

    Dimension 200 Weekly Inspection Component What To Check For Z axis ways Debris buildup X and Y axis ways Debris buildup Electrical box air filter Debris buildup on filter element Weekly Cleaning The weekly cleaning and maintenance procedures include the...

  • Page 101: And Y Axis Ways

    Cleaning and Maintenance X AND Y AXIS WAYS See the photograph under the “Daily Cleaning” section for parts identification. 1. Use a lint-free cloth to clean the X and Y axis ways. 2. Lightly oil the X and Y axis ways with a light machine oil. ELECTRICAL BOX AIR FILTER The air filter is located on the electrical box.

  • Page 102: Router Motor Lubrication

    Dimension 200 ROUTER MOTOR LUBRICATION The router motor bearings are lubricated during assembly but must be lubricated after every 1000 hours of operation. This procedure refers to the High Frequency Spindle Motor Option only. 1. Use a lithium-based, NLGI grade 2 grease, such as Optimal Longtime PD2 or Leuber Isoflex LDS 18 Special A.
  • Page 103 air filter ..........97 Index daily..........92 lead screws ........94 mist coolant tank and nozzle..95 supplies..........93 Absolute X,Y ........52 weekly..........96 Acrylic........77, 78, 79 work table........93 Aluminum .........33 X and Y axis ways ......97 ARC Station........16 Z axis ways........96 connect to GA........22 Collets ..........68 display panel .........40 Coolant ..........86 front panel ........40...
  • Page 104 Language ...........60 Start/Stop ........43 Lead screws.........92, 94 Stop..........45 Low-tack tape ........79 Z Init .........36, 49 Main power switch ......38 Gerber Cool coolant ....25, 86 Mat milling data.......72 Grid engraving .........73 Material selection ......77 grid numbers.........75 Menu Select mode......48 normal ..........73 Menu selection with T-Vac ........76...
  • Page 105 Index Output repeats ........56 Slew ..........42, 81 Speed controller......4, 6 installation........30 Speed Controller System....31 Paneled jobs ........56 Spindle speed........31 Pause mode ........45 Spray adhesive .........79 Plastics .........77, 79 Start Job ..........44 Point of orientation ......41 Start Mode........43, 48 Power connections ......22 Start position........37 Power switch Start Ready ........43...
  • Page 106 Dimension 200 Units ...........60 Vacuum hose........19 Weekly Cleaning ......96 Weekly Inspection......96 Wood ........77, 78, 79 Work clamps ........81 Work Space..........3 Workpiece attachment ........78 mounting ........81 using double-sided tape ....80 using spray adhesive ....80 using tape ........79 X axis ..........35 X axis ways........97 cleaning..........94...

  • Page 107: Table Of Contents

    Table of Contents INTRODUCTION.......................1 Manual Contents......................1 Conventions ........................2 Customer Support ......................2 ROUTER REQUIREMENTS .....................3 Work Space Requirements ...................3 Equipment Requirements .....................3 Router Stand......................3 Electrical Box......................3 High Frequency Spindle Option and Speed Controller .........4 Mist Coolant Compressed Air................4 Chip Removal System....................4 T-Vac Vacuum System ..................4 Electrical Requirements....................4 Router Package Contents....................7...
  • Page 108 OPTIONAL EQUIPMENT INSTALLATION ..............25 Mist Coolant System ....................25 Installing the Mist Coolant System..............26 T-Vac Vacuum System....................29 Speed Controller System ....................31 Using the Speed Controller System ..............32 Engraver Vacuum System Option ................33 SAFETY GUIDELINES ....................35 OPERATING PRINCIPLES .....................37 Overview........................37 X, Y, Z Axes.......................37 Z Axis .........................38 Job Home Position......................39 Power Switch......................40...
  • Page 109 Cutting Tools......................69 Tool Information ....................69 Collets ........................70 Tool Installation ....................71 Tool Removal.......................73 Pen Tool Replacement ..................74 Replacement Cutters ....................74 Table Mats ........................75 Mat Milling ......................75 Grid Engraving ......................76 Normal Grid Engraving..................76 Grid Engraving with T-Vac Option ..............79 Material Selection and Preparation ................80 Routable Materials ....................80 Choosing Sacrificial Material ................81 Attaching the Workpiece to Sacrificial Material............81...
  • Page 110 Weekly Cleaning ......................100 Z Axis Ways.......................100 X and Y Axis Ways ...................101 Electrical Box Air Filter..................101 Router Motor Lubrication ..................102...

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