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This document may not be reproduced by any means, in whole or in part, without written permission of the copyright owner. This document is furnished to support the GERBER EDGE FX. In consideration of the furnishing of the information contained in this document, the party to whom it is given assumes its custody and control...
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FCC Compliance Warning: Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules.
Network connection to a network router equipped with DHCP...........7 Using direct connection ..........................8 Setting the network address of the GERBER EDGE FX from the printer keypad .......9 Setting the IP Address and Network Mask of your computer for direct connection....12 Using network connection with static addresses ................16...
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Chapter 4: General hand tools, special tools, and materials........46 General hand tools..........................46 Special tools ............................47 Materials..............................47 Chapter 5: The GERBER EDGE FX via the Web Interface ..........48 Opening the GERBER EDGE FX web interface .................48 Changing System Settings ........................49 Changing the printer name .......................49 Changing the System Log Level .......................50...
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The vinyl ............................113 The foil..............................113 Chapter 8: Cleaning Procedures..................114 Material and Foil Handling ........................114 Storing the material ..........................114 Cleaning the material ........................114 Normalizing the material ........................114 Handling the foil..........................114 Storing and cleaning the foil ......................115 Maintenance ............................115 Cleaning the print head ........................115 Cleaning the sprockets, bail arms, and squeegees ...............116 Cleaning the platen...........................117 Cleaning the foil squeegee.......................117...
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Establishing the print line alignment ....................166 Replacing the print head........................167 Aligning the Print head........................168 Fine tuning the print head ........................169 Replacing the Z-axis motor and lead screw ..................170 Replacing the Z-axis lead screw nut....................171 Appendix A: EDGE FX Spare Parts ..................172...
Chapter 1: Introduction This manual covers service information for the Gerber EDGE FX. Only qualified technical personnel with the correct tools should perform service and repair actions. Before performing any service, keep in mind the following points. ♦ Read all directions completely BEFORE performing any service procedures.
Electronic versions of this manual and other documentation are available from the eService Document Library which can be accessed from the Gerber web site: www.gspinc.com under “Support.” You must sign up for a free customer account to access the eService location.
38kg Recommended material EDGE READY materials are the only materials recommended for use with the GERBER EDGE FX thermal printer. EDGE READY materials are processed, prepared, and qualified for optimum image quality when printing with the GERBER EDGE® series of printers. They are...
Chapter 2: Specifications Power requirements The GERBER EDGE FX requires the following power: 100-240 V AC, 10 Amp, 47-63 Hz WARNING: All power cables used must meet power requirements. WARNING: Double pole neutral fusing. Terminal for connection of protective earthing conductor.
♦ Microsoft Windows Required: Windows 98, Windows 2000 (second edition), and Windows Environmental requirements The GERBER EDGE FX should be installed in a room that is relatively clean and dust-free. The recommended working environment is as follows: ♦ Operating temperature: 50º to 95º F / 10º to 35º C, ♦...
Network connection to a network hub or switch using static addresses Some locations may connect the EDGE FX to a new or existing network that uses static network addresses. Two typical scenarios are shown in the following illustrations: a new network or an existing network.
Some locations may activate DHCP (dynamic host configuration protocol) on the GERBER EDGE FX and allowing a network equipped with a DHCP server to automatically assign addresses. Two typical scenarios are shown in the following illustrations: a new network with...
DHCP server, the computer automatically selects a network address using Windows Automatic IP Addressing. The range of IP addresses in Automatic Private IP Addressing are as follows: ♦ 169.254.000.000 to 169.254.255.255 The default network address of the GERBER EDGE FX falls with in the range of Automatic Private IP Addressing:...
Setting the network address of the GERBER EDGE FX from the printer keypad The default address for the GERBER EDGE FX was chosen to work with a crossover cable and Windows Automatic Private IP Addressing. For computers that have not been configured for networking, the default address should be acceptable.
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If necessary, replace the network address in this procedure with the proper address obtained from your network administrator or IT professional. To set the network address of the GERBER EDGE FX from the printer keypad 1 From the MAIN MENU use F1 to toggle to OFFLINE.
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Continue until the entire IP Address is updated. Note: This procedure uses the default IP address of the GERBER EDGE FX as an example. Your IP address for the printer may be different.
14 Press F3, CANCEL to exit the menu and return to the MAIN MENU. 15 Cycle the power to the GERBER EDGE FX. The network address will be active after cycling the printer power. Setting the IP Address and Network Mask of your computer for direct...
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Note: Depending on your setup, your computer's IP address may vary. 6 On the IP Address tab, click Specify an IP Address: 7 Enter 169.254.128.130 for the IP Address. 8 Enter 255.255.000.000 for Network Mask. 9 Do not enter a Gateway address; it is not required for direct connection. 10 Click OK to close the TCP/IP Properties dialog box.
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Chapter 2: Specifications 6 Click Properties to open the Internet Protocol (TCP/IP) Properties dialog box. Note: Depending on your setup, your computer's IP address may vary. 7 Click Use the following IP address: 8 Enter 169.254.128.130 for IP Address. 9 Enter 255.255.000.000 for Network Mask. 10 Do not enter a Default Gateway;...
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2 Double-click the Network and Dial up Connections icon. 3 Right-click the Local Area Connection icon and choose Properties from the context menu to display the Local Area Connection Properties dialog box. 4 Click Internet Protocol (TCP/IP) in the list. 5 Click Properties to open the Internet Protocol (TCP/IP) Properties dialog box.
Ethernet cables with RJ45 connectors (or crossover cables if the switch is auto-sensing): one cable to connect the GERBER EDGE FX and the switch and one to connect the computer and the switch. The Ethernet switch, network interface board, and additional cables are readily available at local computer stores.
CAUTION: Use care when entering addresses for the equipment. Entering an incorrect address could damage the network. In a large existing network, obtain the correct address for the computer and the GERBER EDGE FX from the network administrator or IT professional.
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Chapter 2: Specifications Note: Depending on your network and other equipment currently residing on the network, your computer's IP address may vary. If necessary, replace the network address in this procedure with the proper address obtained from your network administrator or IT professional.
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5 Click Internet Protocol (TCP/IP) in the list. 6 Click Properties to open the Internet Protocol (TCP/IP) Properties dialog box. Note: Depending on your network and other equipment currently residing on the network, your computer's IP address may vary. If necessary, replace the network address in this procedure with the proper address obtained from your network administrator or IT professional.
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Chapter 2: Specifications To set the IP Address and Network Mask for Windows 2000 1 Click Start > Settings > Control Panel. 2 Double-click the Network and Dial up Connections icon. 3 Right-click the Local Area Connection icon and choose Properties from the context menu.
IP Address from the IP Address pool. By default DHCP is disabled on the GERBER EDGE FX to allow you to assign a static network address. You can active DHCP from the GERBER EDGE FX control panel, or from the web interface (if network connectivity has been established).
Ethernet mode is Auto Negotiate and there should be no need to change this for normal printer operation. The GERBER EDGE FX is capable of communicating at the following speeds: ♦ Auto Negotiate (printer automatically determines the speed – factory default) ♦...
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To set the Ethernet mode 1 From the MAIN MENU use F1 to toggle to OFFLINE. MAIN MENU OFFLINE CANCEL Mode: Single SYSTEM 2 Press F4, SYSTEM to display the SYSYEM MENU. SYSTEM MENU NETWORK CANCEL DIAG MOTION 3 Press F1, NETWORK to display the NETWORK MENU. NETWORK MENU TCP/IP CANCEL...
Chapter 2: Specifications Checking network connections You can check the network connections to be sure that the computer and GERBER EDGE FX can communicate. Tip: When a live network cable is plugged into the computer, the RJ45 jack LEDs will light.
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3 Click the Network tab. 4 If the GERBER EDGE FX is visible on the network it is shown in the Devices Found drop down list. Choose the printer to install from the list. Click the Browse button to navigate to the printer location.
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8 Click OK to return to the Add or Delete Gerber Vinyl Printer(s) dialog box. 9 Click the Device Home page button if you wish to open the web interface of the GERBER EDGE FX. Once open, you may wish to make a shortcut on your desktop for easy access.
Chapter 3: Theory of Operation Proper servicing of the GERBER EDGE FX depends on a thorough understanding of its operating principles. The purpose of this section is to: ♦ give you an overview of EDGE FX o peration ♦ describe the relationships among the parts ♦...
Owner’s Guide provided with the EDGE FX. 1 The EDGE FX is a network printer. It can make a direct connection to a computer with a cross-over Ethernet cable or can be connected to a network.
♦ Controls foil supply (foil movement using the foil motor to drive the take-up clutch) Initialization sequence overview After the EDGE FX is turned on the following occurs, if there are no start-up problems: ♦ There will be one beep if the SRAM test passed, and the LCD should be displaying two long black bars ♦...
Owner’s Guide provided with the EDGE FX. After a job is sent to the EDGE FX, the printer is in the “paused” mode. The user presses F1 (PAUSED) and the printer goes into ONLINE/PRINT mode. Messages on the LCD prompt the operator to load the vinyl and foil.
Chapter 3: Theory of Operation Parts and their functions The major parts of the GERBER EDGE FX are the chassis, the platen assembly, and the print head assembly. These parts are generally described on subsequent pages. The chassis ♦ The power switch and power cord receptacle are located on the back of the printer.
The bail arm squeegees clean the area to be printed. ♦ The EDGE FX does not operate if the out- of-vinyl sensor determines that no vinyl is loaded or if the EDGE FX runs out of vinyl...
The keypad and display are used to change operation modes, to enter operator responses and commands, and to display instructions for the operator. Four of the keys on the EDGE FX front panel are soft keys. Two are dedicated slew keys (however, there are exceptions when the slew keys are used for other functions, e.g.
Chapter 3: Theory of Operation BootStrap Flowchart Follow this flowchart for troubleshooting before the first two beep codes are heard when powering the printer on. Troubleshooting after the second beep code is summarized in the next section.
BootLoader is loaded and run, no third beep code will be heard. Resetting to Factory Parameters The EDGE FX has certain parameters set at the factory. If you change these settings, or if an incorrect checksum alters the settings, the EDGE FX may not operate properly. If you suspect a problem, reset the EDGE FX to factory parameters and send your job again.
VERSION Displays firmware version information. Additional diagnostics, for use by Gerber Manufacturing or Service personnel are available in a hidden menu. This hidden menu is activated from the MAIN MENU by simultaneously pressing F2 and F4.
Z-AXIS Use the left and right slew keys to change the position of the Z-axis (move the print head up and down). BLACK 2MIL LABEL Prints 50 % 70.7 LPI halftone. Firing parameters are for black foil on white 2 Mil label stock. This print job runs indefinitely until it is canceled.
Chapter 3: Theory of Operation The following table lists the tests available from the Diagnostics web page. Diagnostic Test Description RFID read only test Continuously either read or read/write to a RFID read/write test cassette RFID tag. Analog Inputs Continuously displays analog input values such as: TPH temperature, TPH VCC, LCD VCC, and RFID VCC.
The following tools are recommended to maintain and repair the EDGE FX. General hand tools General hand tools are used to remove, adjust, and reinstall a variety of EDGE FX parts, including covers, circuit boards, and mechanical components. These tools remove common fastening hardware such as screws.
The cleaning materials are: ♦ rubber gloves ♦ ThermApprove print head cleaning pads (25 pads pre-moistened with 99% isopropyl alcohol). Gerber part number P66530B ♦ a clean, lint-free clot h ♦ 99 percent isopropyl alcohol ♦ a compressed air, ultra-filtered, non-residue dust remover such as Chemtronics® Utrajet®...
The GERBER EDGE FX via the Web Interface Opening the GERBER EDGE FX web interface The GERBER EDGE FX is a network device. You can remotely check the status or change the settings of the GERBER EDGE FX from any computer connected to it via the network.
♦ Language used on the display Changing the printer name You can give the GERBER EDGE FX an easily identifiable name displayed in the web interface on the System Settings page. The default name is Gerber Thermal Printer. To name the GERBER EDGE FX printer 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
Gerber Technical Support for diagnostic purposes. To change the System Log Level 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
4 Examine the job; if the overlap setting produces acceptable results, you are finished. If not, continue with this procedure to adjust the overlap. 5 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
Overlap value will return to 15 pixels. You will need to reset the Overlap value. Changing the display scroll speed You can alter the rate that messages scroll on the GERBER EDGE FX LCD. The default setting is Slow. To change the display scroll speed 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
Changing the Foil Display/Speed You can alter the rate that foil messages alternate, and whether to display the foil name only, or the foil name and the length on the GERBER EDGE FX LCD. The available settings are: ♦ Name Only (Slow) ♦...
To change the material selection list 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
Choosing the numeric units The units used on the GERBER EDGE FX and on the web pages can be chosen via the System Settings page of the web interface. The choices are: Inches, Feet, Yards, Centimeters, and Meters. The default numeric unit is Inches.
2 Click the System Settings link to open the System Settings page. 3 Choose a language from the drop down menu. 4 Click Change Settings to apply the new language to the GERBER EDGE FX and to the web interface pages.
To enable or disable Out of Vinyl or Cover Sensors 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
GERBER EDGE FX to your computer” on page 5. By default the GERBER EDGE FX is set to use Static Settings. If you have a DHCP server on your network, you can set the printer to use DHCP instead of static addresses. See “Using DHCP”...
The Use DHCP button activates the settings provided by a DHCP (dynamic host configuration protocol) server rather than the static settings. DCHP can also be set at the GERBER EDGE FX control panel. See “Using DHCP to assign network address” on page 21.
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Address pool. The address may vary from session to session. Your network administrator must define the starting and ending addresses of the pool. You must cycle the power to the GERBER EDGE in order for the DHCP settings to be in effect. To activate DHCP 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http:// 169.254.128.129).
You can update the GERBER EDGE FX firmware to a new revision level using the web interface. When an update file is sent to the GERBER EDGE FX, (using the Send button) it programs new firmware onto the printed circuit board of the printer. The GERBER EDGE FX must be set to OFFLINE in order to update the firmware.
Gerber or visit the Gerber web site (www.gspinc.com). To view Gerber contact information 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
Chapter 6: Messages This section provides information for: ♦ List of EdgeFX menus ♦ Reestablishing factory default settings ♦ Display of error codes and messages ♦ Identifying and correcting error messages EdgeFX Menus Menu Description The main menu. This is the first menu to be MAIN MENU OFFLINE...
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Chapter 6: Messages Displays the MATERIAL (a.k.a. “vinyl”) to be used MATERIAL MENU CANCEL for the print job. The user is allowed to select a SUBSTITUTE MOTION F4 substitute material by pressing F2. NOTE: substitution not available when running a “legacy” print job (i.e.
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The network throughput test. Network Test CANCEL Quality: Rate: Kbyte/sec Displays the firmware release version. This is the GERBER EDGE FX CANCEL version for the overall release (which includes all Release: NEXT firmware components). 1 of 9 Displays the application firmware version.
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Chapter 6: Messages Displays the language version. GERBER EDGE FX CANCEL Language: NEXT 5 of 9 Displays the FPGA version. GERBER EDGE FX CANCEL FPGA: NEXT 6 of 9 Displays the history control version. GERBER EDGE FX CANCEL History: NEXT 7 of 9 Displays the Fire File version.
Press any key to continue. This message can only be displayed during the boot sequence. Unhandled [ERROR] Displays unhandled Report error code to Gerber Exception exception code. This is used Service department. Number nnn to display a low-level microprocessor reported error.
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Chapter 6: Messages System update in The firmware is being progress, please stand updated. This phase of the by… update can’t be canceled. Rebooting system The system is being re-booted Please stand by… after a firmware update. Error! Z-axis not cal. [ERROR] Z-axis hasn’t been Refer to the section on z-axis calibrated.
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Check Foil! [ERROR] The end of the foil Insert another foil cassette. If RETRY/CANCEL has been reached (or the foil the foil is broken, then it can has broken). The job is be repaired with tape before resumed when the RETRY re-inserting the cassette.
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Press CANCEL (F3) to return out in the job. Check material firmware. to the MATERIAL MENU. used in job. Update firmware CANCEL in EDGE FX –this also updates the internal Fire File. Unknown Foil! [WARNING] The foil in the Internal Fire File doesn't CANCEL job or in the cassette is support the foil.
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Press any the job. Update firmware in key… EDGE FX – this also updates the internal Fire File. IP address used after The saved IP address will be Cycle power so selected IP reboot.
Chapter 6: Messages Edge FX Error Codes NOTE: Error codes 1 – 6, 11 – 13 are not displayed on the front panel, instead they will be displayed on the four LEDs located on the CPU board. The error code is reported as a binary number with the LEDs having the following binary weights: •...
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Operating system semaphore error. Same recommended action as Operating system semaphore overflow error. Same recommended action as Operating system critical region error. Same recommended action as A value is out of range. Same recommended action as There is no more input data. Same recommended action as Not a number (NAN).
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Chapter 6: Messages RFID tag error – command not recognized. Same recommended action as 105. RFID tag error – command option not Same recommended action as supported. 105. RFID tag error – specific error code not Same recommended action as supported.
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UNKNOWN from this point on. Use GerberGauge. CRC error for RFID tag read/write data. Same recommended action as 160. Incorrect EDGE FX RFID tag version Incompatible cassette RFID tag. Remove RFID tag from cassette. Cassette will be handled as UNKNOWN from this point on.
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Unable to start print H/W. Print engine hardware couldn't start. Cycle power to unit. If problem persists, update firmware and/or control board. Print start, already printing. Internal error. Cycle power. Print start, no buffers Internal error. Cycle power. Unable to load Thermal Print Head. Internal error.
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Chapter 6: Messages Error occurred when selecting network input. Same recommended action as 800. Timeout occurred when selecting network Same recommended action as input. 800. Error occurred when reading network input. Same recommended action as 800. Error occurred when writing data to network Same recommended action as host.
The default setting is 0.0.0.0 for none. IP Address 169.254.128.129 valid IP IP address of GERBER EDGE FX. Enter a address unique IP address for network to which the GERBER EDGE FX will be physically connected. Network 255.255.0.0...
A line through the length of a job along the X-axis First, clean the print head and foils. See “Cleaning the GERBER EDGE FX”. If that does not work, change the print settings to Dark or Darker in the GSPPlot program. In GSPPlot, click Settings in the Print Options dialog box to open the GERBER EDGE Print Settings dialog box.
Backing/Finish button from the Print Options dialog box of GSPPlot. The top or bottom of a job is consistently darker than the rest There may be a print head pressure problem. Please call your distributor or Gerber Service. Light Spots in a repeating pattern in the job Clean the platen.
Chapter 7: Troubleshooting Diagnosing printer problems The DIAGNOSTIC MENU of the GERBER EDGE FX provides a small test print to verify that the printer is capable of printing and a network test to determine the network throughput. From the DIAGNOSTIC MENU you can also view the firmware version information which you may need if speaking with Gerber technical representatives.
4 Press F1 to print the job. The display changes to: MATERIAL MENU CANCEL SUBSTITUTE HOME Need: 3m Scotchcal Series 220 5 Load the requested material (3M Scotchcal Series 220 Premium Film) and press F1, OK. The display changes to: FOIL MENU CANCEL HOME...
The job data is discarded. Viewing GERBER EDGE FX version menus When troubleshooting the GERBER EDGE FX, it may be helpful to determine the versions of firmware components. The easiest way to view the versions is through the DIAGNOSTICS page of the web interface.
3 Press F4, VERSION to open the EDGE FX VERSION menu. Version menu 1 of 9 displays. EDGE FX VERSION Release: CANCEL XX.XX NEXT 1 of 9 4 Press F4, NEXT to display the version menus 2 of 9. Continue to press F4, NEXT to step through all of the menus.
To run the RFID test 1 Open the GERBER EDGE FX web interface by double clicking the icon on the desk top or the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
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4 Click either the Read Only Test or the Read/Write Test to perform that test. The RFID Test Results page displays and updates every five seconds. 5 Click Stop Test to end the test and return to the RFID Tag Diagnostics window. Click Done Testing to return to the Home page.
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♦ Digital Inputs: displays the state of the sensors, drivers, and cables which can be used to troubleshoot the printer in conjunction with GSP Technical Support. ♦ TPH Power: test turns the TPH power supply on and off. Note: The GERBER EDGE FX must be OFFLINE to run diagnostic tests.
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To run the Analog Input test 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129). The Welcome to GERBER EDGE FX screen displays.
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Chapter 7: Troubleshooting To run the TPH Fans test 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129). The Welcome to GERBER EDGE FX screen displays.
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5 Click Foil Motor ON to turn on the GERBER EDGE FX foil motor. 6 Click Foil Motor OFF to turn off the GERBER EDGE FX foil motor. The results of the expected voltage test and the state of the foil motor (ON/OFF) display in the window.
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Chapter 7: Troubleshooting To run the Digital Input test 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129). The Welcome to GERBER EDGE FX screen displays.
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To run the TPH Power test 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129). The Welcome to GERBER EDGE FX screen displays.
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The default setting is 1 (lowest) which records only the major errors and should be adequate for most users. The highest setting records all messages sent to the GERBER EDGE FX and is usually used by Gerber Technical Support for diagnostics. When the System Log is turned off (set to 0 (OFF)) no messages are recorded.
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3 Click the Keypad link to open the EDGE FX Keypad Diagnostics page. 4 Press the keys on the GERBER EDGE FX keypad one at a time or multiple keys at the same time and then click the Read Keys button. If the keys pressed match the displayed information the keypad is functioning properly.
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To run the Burn-In test 1 Open the GERBER EDGE FX web interface by entering the printer's IP address in the Location or Address line of your web browser (for example: http://169.254.128.129).
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Tip: If the LCD is disabled, you can continue to run the GERBER EDGE FX to complete a job in progress. See the current LCD messages on the home page of the web interface. See “Opening the GERBER EDGE FX web interface”...
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The Statistics link offers several diagnostic statistic pages that can be useful when troubleshooting printer operation. The statistic pages provide information on the settings or status of the printer. You can not alter these settings. Click the Statistic link from the GERBER EDGE FX Diagnostics page to open the Statistical Diagnostic page.
Charts for identifying and correcting situations Supplement the possible causes and remedies that are described in the charts with information from the Chapter 3: Theory of Operation. The troubleshooting charts are arranged by the following situations: ♦ situations involving vinyl and foil ♦...
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The clamp on the take up clutch is loose Remedy Tighten the clamp. Possible cause Foil not moving properly through the EDGE FX Remedy Go to “Check Foil error on the LCD,” for additional actions. Check supply roll plate assembly...
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Possible cause The bail arm is not holding the vinyl down Remedy Run vinyl through the EDGE FX with the head up and verify that the bail arm and associated hardware are working properly. Adjust the bail arm as necessary.”...
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Chapter 7: Troubleshooting Situation Static cling vinyl goes off track Possible cause No transfer tape on the vinyl squeegees Remedy Put transfer tape on the vinyl squeegees as described in the product bulletin that comes with the vinyl. Possible cause The sprockets are dirty Remedy Clean the sprockets with isopropyl alcohol and a...
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Situation Magnetic vinyl goes off track Possible cause The vinyl is sticking to the metal parts of the EDGE FX Remedy Cover the metal parts as described in the product bulletin that comes with the vinyl. Possible cause The vinyl is sticking to itself...
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Chapter 7: Troubleshooting Situation Vinyl tracking problems Possible cause Not using Gerber vinyl Remedy Use EDGE Ready™ vinyl. Possible cause Improper settings in OMEGA Remedy Verify that the correct vinyl is selected in OMEGA. Possible cause Damaged or dirty vinyl and foil squeegees Remedy Clean or replace the vinyl squeegees.
Printing and data transfer Situation Data Error on LCD/EDGE FX is printing in the middle of a job Possible cause Loose cable connections Remedy Check the cable connections from the PC to the GERBER EDGE FX. Possible cause Temporary, unknown fault, or GERBER EDGE FX and...
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Improper settings in OMEGA Remedy Verify that the correct vinyl is selected in OMEGA. Possible cause Improper EDGE FX light/darkness settings Remedy Change the setting to lighter (Plot Print Order dialog box). See your Omega Reference Manual for more information.
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Possible cause Print head damage Remedy Run internal test pattern to 5 to verify the condition of the print head. Replace the print head if necessary. Possible cause Pixel blown in the print head Remedy Replace the print head. Situation Vertical lines in the printed area Possible cause Cartridge problem...
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Possible cause Loose cable connections Remedy Check and reseat the parallel data cable from the computer and the EDGE FX. Situation The top or bottom of a job is consistently darker than the other Possible cause...
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Improper settings in OMEGA Possible cause Remedy Verify that OMEGA is set to print on the vinyl loaded in the EDGE FX. Situation Opacity problems, such as a light color (like yellow) not covering a dark color (like purple) Possible cause...
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15 minutes. Check the vinyl path through the EDGE FX and verify that the vinyl does not bind and moves smoothly. Also, refer to “Holes in the vinyl are elongated or ripped”.
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15 minutes. Check the vinyl path through the EDGE FX and verify that the vinyl does not bind and moves smoothly. Also, go to “Holes in the vinyl are elongated or ripped”.
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Chapter 7: Troubleshooting Possible cause Printed images stacked print-side to print-side Remedy Stack the printed side contacting the liner side of another piece of vinyl or use a paper interleaf between the layers. Possible cause Clutch problems Remedy Replace the foil take up and/or supply clutches. Possible cause Foil motor failure Remedy...
EDGE FX. Do not soak the foil – just spray it enough to blow the dust off the foil. If the color cartridge is in the EDGE FX, use the foil slew key to advance the foil several inches so that the dirt buildup is rolled beyond the print head and into the color cartridge.
Before loading material into the GERBER EDGE FX, wipe the ends of the roll with a tack cloth to remove any dirt or dust. Tip: An easy way to clean the material before printing is to slew as much as you are going to use through the GERBER EDGE FX and back again.
Chemtronics® Ultrajet®. If the contaminates can not be removed, slew the foil when it is loaded in the GERBER EDGE FX so that the area is rolled beyond the print head.
Chapter 8: Cleaning Procedures is degraded and a more thorough cleaning is necessary. We suggest cleaning the print head element weekly or as required. Print head Foil squeegee Cleaning the sprockets, bail arms, and squeegees Wipe the bail arm squeegees and bail arm with GSP cleaning pads which are impregnated with 99% isopropyl alcohol or a clean, lint-free cloth moistened with 99% isopropyl alcohol.
Sprockets CAUTION: Do not dip the brush in alcohol because excess alcohol can drip into the GERBER EDGE FX and cause damage. Wipe the sprockets with GSP cleaning pads or a clean, lint-free cloth moistened with 99% isopropyl alcohol. Allow the sprockets to air dry before loading material.
Chapter 8: Cleaning Procedures Foil squeegee Print head Replacing the foil squeegee Remove the four Phillips head screws that attach the foil squeegee making note of its position. Discard the squeegee. Attach the new foil squeegee using the same screws. Replacing the bail arm material squeegees Remove the two material squeegees by peeling them off the bail arms and discarding them.
Note: Read each procedure through in its entirety before performing it. Note the relationship of parts prior to disassembly so that you can easily reassemble the EDGE FX. Disassemble the EDGE FX to the minimum extent necessary to repair or replace parts.
It is extremely important that the output voltage of the power supply is calibrated to the resistance of the print head. The most efficient way to do this is to order a power supply calibrated by Gerber at the factory for the print head existing in the EDGE FX. Therefore, before removing the power supply: To determine the print head resistance 1 Lift the top cover.
4 Take out power supply. Installing the power supply After installing the power supply, verify that the power supply is calibrated for the print head resistance. If it is not, adjust the power supply voltage to the print head as described in the section titled, “Adjusting the power supply voltage to the print head.”...
2 Insert a small flat screw drive into the notch from below and gently pry the fuse carrier plate out. 3 Remove the blown out fuse(s) from the carrier and insert new fuse(s). 4 Insert the fuse carrier into the GERBER EDGE FX with the notch down and snap into place. 5 Reconnect the power cord.
To install new circuit board 1 Put new board into EDGE FX, careful to line up Ethernet port first with the back cover. 2 Line up right side of the circuit board, careful not to hit the X-axis stepper motor.
Allen head screw Recalibrating the circuit board After installing the circuit board with NO foil in the EDGE FX, on power up you will get a Z error. This is normal. You will now need to input the three settings.
VDC. 8 Read the resistance on the print head’s manufacturing label. 9 Refer to the EDGE FX Power Supply Voltage Settings table on the next page to determine the correct voltage setting for the print head resistance.
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Chapter 9: Replacing Electrical Parts EDGE FX Power Supply Voltage Settings Print head resistance range Correct VDC reading 1135-1139 20.7 1140-1152 20.8 1153-1165 20.9 1166-1178 21.0 1179-1192 21.1 1193-1205 21.2 1206-1218 21.3 1219-1232 21.4 1233-1246 21.5 1247-1259 21.6 1260-1273 21.7 1274-1287 21.8...
To remove the print head data cable 1 Before powering down the EDGE FX, lower the print head so it will be easier to access. 2 Open the top cover and remove the left side panel.
7 Remove the vinyl motor from the backside of the EDGE FX front panel. To replace the vinyl motor 1 Insert the new vinyl motor through the backside of the EDGE FX front panel. 2 Attach the four screws (4mm) that holds the vinyl motor to the plate.
EDGE FX turned off and unplugged from the power source. CAUTION: Static electricity is a serious threat to modern integrated circuits. Before reaching into the EDGE FX or handling any components, touch any bare metal of the chassis. This discharges any potentially harmful static electrical charge being carried.
Chapter 9: Replacing Electrical Parts Replacing the Sensors There are six sensors that can be replaced on the EDGE FX: ♦ X-axis home ♦ Vinyl Sensors (2) ♦ Z-axis home ♦ RFID reader (foil encoder) ♦ Cassette (2) ♦ cover...
Replacing the vinyl sensors To remove the vinyl sensors 1 Remove the left side cover and disconnect the operator control panel connector from the circuit board. 2 Remove the bottom front cover by opening the unit and removing the two screws (Phillips).
Chapter 9: Replacing Electrical Parts Replacing the cover-down sensor To remove the cover-down sensor 1 Remove the bottom front cover. 2 Remove the 2 attachment screws (2.5 mm) securing the sensor in place on the chassis. 3 Unplug the cable connecting the sensor to the circuit board through the opening in the front of the chassis.
Replacing the Z-axis home sensor To remove the Z-axis home sensor 1 Remove the top cover, top front cover, and the lower left side panel. 2 Open the printer cover and make sure the bail arm is down. Use the control panel on the machine to move the Z-axis down.
To remove the foil cassette sensors 1 Remove the top cover. 2 Lift the cover of EDGE FX. 3 The sensors are located on one of the static brush mounts (see picture below). 4 The cassette sensors are labeled cass 1 (bottom sensor) and cass 2 (top sensor). Change the sensors one at a time.
Replacing the RFID reader To remove the RFID reader 1 Open the printer cover and make sure the bail arm is down. 2 The RFID reader is located in between the two foil cartridge sensors. 3 Remove the two screws (2.5mm) securing the RFID reader to the head mount frame. 4 Unplug the cable attached to the RFID reader.
Note: Read each procedure through in its entirety before performing it. Note the relationship of parts prior to disassembly so that you can easily reassemble the EDGE FX. Disassemble the EDGE FX to the minimum extent necessary to repair or replace parts.
2 Use the controls of the EDGE FX to move the Z-axis all the way down. 3 Open the EDGE FX to reach the two screws (3mm) on the inside of the cover. 4 Use an extended 3mm T-handle to reach the screw on the right side of the top cover from the inside.
1 Make sure all the plastic pins are aligned with their respective slots or the cover will not fit properly. 2 Use the controls of the EDGE FX to move the Z-axis up. Attach the top screw (Phillips). 3 Move the Z-axis all the way down.
To remove the bottom front cover 1 Remove the two screws (3 mm) with washers on the bottom of the chassis. 2 Open the EDGE FX. 3 Remove the two screws (Phillips grip-on might be necessary) on either side of the bail arm.
Chapter 10: Replacing Mechanical Parts Back Panel To remove the back panel 1 Remove the five screws that attach the back panel to the chassis. To replace the back panel 1 Attach the five screws that hold the back panel to the chassis.
Adjusting the bail arm WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. An improperly adjusted bail arm can contribute to vinyl tracking problems. If the bail arm is pressing too tightly against the vinyl, it can cause the vinyl to bind or otherwise disrupt the movement of vinyl through the EDGE FX.
WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. There are two pressure feet on the underside of the bail arm − one at the front near the bail arm latch button and the other at the rear.
WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. CAUTION: To avoid damaging the EDGE FX cover and support blocks, always replace the gas springs in pairs. To remove the cover support gas springs 1 Remove both the back cover and top cover.
Replacing the timing belts WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. Note: It is recommended that both belts be replaced even if only one belt needs replacing for both the front and small timing belt systems.
Setting the front belt tension Setting the front belt tension 1 With the front cover off and the printer turned off, hook the tension device to the front belt pulley system with the two springs (see pictures below). Make sure the screw sticking out of the back left of the tension device fits into the groove in the chassis.
Chapter 10: Replacing Mechanical Parts Replace the small timing belts under the platen To remove the small timing belts under the platen 1 Remove the front and lower side covers. 2 Loosen the collar clamp connected to the larger pulley located on the end of the sprocket shaft (see “Replacing the timing belts”...
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To replace the small timing belts under the platen 1 Install the platen drive assembly with the belts back in proper location. 2 Attach left screw (4mm) and load the spring. 3 Slide the shaft back into place. 4 Slide the large belt on. 5 Put platen back in.
Replacing the Platen WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. To remove the platen 1 To replace the platen, the front and lower side covers must all be removed.
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To replace the platen 1 When installing the new platen, slide the sprocket shaft back towards the rear making sure both rear belts are slid over the top of the shaft. 2 Install the two screws (3mm) that attach the rear platen bearing block to the chassis. 3 Install the rear floating sprocket.
Chapter 10: Replacing Mechanical Parts Checking and setting sprocket alignment Each sprocket has a v-shaped cutout in the edge. The platen housing also has a v-shaped cutout at the front and rear. When these v-shapes are aligned, as shown in the illustration, they form a diamond-shaped hole that a 3/16"...
Replacing the front platen bearing WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. To replace the front platen bearing 1 Remove the bottom front and lower side covers and open the printer.
To lubricate the lead screw 1 Remove the foil/caddy from the EDGE FX. 2 Lift the top of the EDGE FX printer until it is fully extended and comes to rest in the upright position. Lid will be all the way up.
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4 Place a pea-sized dab of lubricant onto the mid-point of the visible portion of the lead screw and work into threads. The lead screw is visible behind the print head. Avoid contact with other parts or surfaces. 5 Operate the printer as usual. When the print head is lowered and raised, the movement of the lead screw will bring the lubricant into contact with the Z-Axis nut.
Replacing the static strip WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. To replace the static strip 1 Slide the static strip out of the slot in the head mount assembly.
Note: Read each procedure through its entirety before performing it. Note the relationship of parts prior to disassembly so that you can easily reassemble the EDGE FX. Disassemble the EDGE FX to the minimum extent necessary to repair or replace parts.
2 Use the control panel to move the Z-axis all the way down. 3 Remove the three screws (2.5mm) securing the clutch plate which can be done through the circular opening on the front of the EDGE FX. (see picture “Replacing the foil take- up clutch”).
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9 Replace the three screws (2.5mm) securing the clutch plate which can be done through the circular opening on the front of the EDGE FX. 10 Lastly, in the manufacturing menu #3, press F2 (Z-axis) and press the slew foil button.
2 Use the control panel to move the Z-axis all the way down. 3 Remove the three screws (2.5mm) securing the clutch plate which can be done through the circular opening on the front of the EDGE FX. (see picture “Replacing the foil take- up clutch”).
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3 Tighten the two set screws (2mm) through the rectangular hole in the take-up clutch housing. 4 Replace the three screws (2.5mm) securing the clutch plate which can be done through the circular opening on the front of the EDGE FX.
Replacing the foil supply clutch WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. To remove the foil supply clutch 1 Remove the top front cover and open the printer.
2 Use the control panel to move the Z-axis all the way down. 3 Remove the three screws (2.5mm) securing the clutch plate which can be done through the circular opening on the front of the EDGE FX. (see picture “Replacing the foil take- up clutch”).
Note: Read each procedure through in its entirety before performing it. Note the relationship of parts prior to disassembly so that you can easily reassemble the EDGE FX. Disassemble the EDGE FX to the minimum extent necessary to repair or replace parts.
Replacing a head mount cooling fan WARNING: To avoid electric shock, perform all maintenance procedures with the EDGE FX turned off and unplugged from the power source. The fans are located under the top cover. To remove a head mount cooling fan 1 Remove the top cover.
This procedure may need to be performed after changing a Printhead. To reset the print time to zero 1 Open the GERBER EDGE FX web interface by entering the Printer’s IP address in the Location or Address line of your web browser. The Welcome to GERBER EDGE FX screen displays.
3 Press F1 (OK), the Foil Menu appears. 4 Press F1 (OK), the EDGE FX will print a blue square, when about 12” to 18” has printed, you must stop the job or it will keep printing. 5 Review the print quality of the square and make adjustments accordingly.
• Motion F4 • Home F4 4 Load White 225 vinyl and spot black color foil into the EDGE FX. 5 Run the print line alignment test. • Push and hold F2 then press F4. Push F1 for alignment test 6 Open the bail arm and place the alignment template (T56310C) over the vinyl.
The following procedures describe how to remove and install a replacement print head in an EDGE FX while maintaining proper factory alignment between the supply roll, the print line, and the platen. The parallel relationship between the supply roll axis and the platen is critical.
3 Press F1 (PAUSED), the Material Menu appears. 4 Press F1 (OK), the Foil Menu appears. 5 Press F1 (OK), the EDGE FX will print a line. To review printed line 1 Place the print line template (T56310C) onto the vinyl and fit into the sprocket holes.
3 Press F1 (OK), the Foil Menu appears. 4 Press F1 (OK), the EDGE FX will print a black square, when about 12” to 18” has printed, you must stop the job or it will keep printing. 5 Review the print quality of the square and make adjustments accordingly.
Chapter 12: Replacing the Head Mount Parts Replacing the Z-axis motor and lead screw To remove the Z-axis motor and lead screw 1 Remove the top cover and turn on the printer. 2 When the printer is on at the main menu press F2 and F4 at the same time to bring up the manufacturing menu.
Replacing the Z-axis lead screw nut To remove the Z-axis lead screw nut 1 Remove the top cover and turn on the printer. 2 When the printer is on at the main menu press F2 and F4 at the same time to bring up the manufacturing menu.
Appendix Appendix A: EDGE FX Spare Parts Material Description Material Description P77038C Arm, Cassette Side Shift P78176A Gas Spring, 60LBS, 3 inch stroke P77006B Arm, Left Sensor Cassette P76950D Handle, Base front cover P77007B Arm, Right Sensor Cassette P77816A Kit, Static Mat...
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P79764B Strap, Static Drain P42838A Tie .19 x 11.50 Heavy Blk. P25585A Tie .10X05.50 MINTR NAT P78795A Tie Down, Ratchet 1”x9” 1000lb. W.L. P80055A 15x5 HP WHITE P80056A 15x5 LBL STK 2M White P79727D Wing, Infeed, right P76934D Wing, Outfeed, left T78262A Tool, Tensioner Belt X-Axis T76523B...
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