Table of Contents

Summary of Contents for Gerber HS15 Plus

  • Page 1: User Manual

    plus HS15 USER MANUAL...
  • Page 2: Copyright Notice

    Knife Mode Switching, Corner Correcting Technology, IP Plus, GerberMask, and HS15 are trademarks of Gerber Scientific Products, Inc. GRAPHIX ADVANTAGE and GerberCal are registered trademark of Gerber Scientific Products, Inc. 3-in-1 is a registered trademark of Boyle-Midway, Inc. HPGL is a registered...
  • Page 3: Fcc Notice

    FCC NOTICE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
  • Page 5: Table Of Contents

    Table of Contents INTRODUCTION..........................1 Support Information ................. 3 Package Contents ..................4 INSTALLATION ..........................7 Assembling the Plotter ................7 Connecting the Plotter ................8 Communication Parameters..............8 Power Cords ..................... 9 Power-up Sequence .................. 9 plus Adding the HS15 Plotter..............
  • Page 6 OPERATION ..........................29 Travel Limits ..................29 Power Up....................29 Front Panel ..................... 30 Slew Keys....................31 Slow slew key .................. 31 Swivel Knife key................32 Init Knife key ................... 33 Run Single key................. 34 Controlled stop................. 34 Single plot exercise................35 Run Cont key ...................
  • Page 9: Introduction

    Swivel Knife Mode cuts faster than tangential knife mode for rapid cutting of all but the most demanding materials, such as sandblast. Gerber's exclusive Corner Correcting Technology ensures sharp, easy-to-weed corners in swivel knife mode. plus...
  • Page 10: About This Manual

    Convenience plus HS15 has many features that make it easy and convenient to use: Accepts any standard Gerber materials in 15-inch wide rolls. Draws, cuts, and pounces up to 13.0 inches high. Using the plus system Panel feature, the HS15...
  • Page 11: Support Information

    Customer support through Gerber Field Service Department. Step-by-step user's manual. plus If you require assistance installing or operating your HS15 plotter, contact your distributor or Gerber Field Service at 800-828-5406 (in the USA), or fax at 203-645-2448.
  • Page 12: Package Contents

    plus HS15 Package Contents plus This section lists the contents of the HS15 shipping carton. As you plus unpack the HS15 plotter, inspect all items for damage that may have occurred during shipping. Report any damage to your distributor at once. Save all packaging materials in case it becomes necessary to transport the plotter at a future date.
  • Page 13 Introduction Tool Kit Contents Below is a list of the contents of the tool kit. The photograph may not contain all the parts listed. Pen holder with pen Tangential knife holder with blade Pounce wheel holder Tool lift washers (on tool holders) Allen wrench Pair tweezers Spare red pen...
  • Page 15: Installation

    INSTALLATION Unpack the plotter boxes and inventory the contents before you begin to plus assemble the plotter. Follow these instructions to install the HS15 plotter to the . If you intend to operate the GRAPHIX ADVANTAGE plus HS15 with software other than the GRAPHIX ADVANTAGE plus please contact your software vendor for an HS15...
  • Page 16: Connecting The Plotter

    plus HS15 Connecting the Plotter CAUTION: Turn off power and unplug the power cord at both and the plotter. GRAPHIX ADVANTAGE 1. Insert the 9-pin connector at the end of the RS-232 cable into the 9- pin RS-232 connector on the back of your GRAPHIX ADVANTAGE This connector is normally labeled Plotter or COM Port 2.
  • Page 17: Power Cords

    Installation The plotter has a 25DB female connector with these pin assignments: Signal Sig Gnd All other pins are not connected. Power Cords plus 1. Insert the female connector of the HS15 plotter power cord into the socket on the rear panel of the plotter. 2.
  • Page 18: Adding The Hs15

    plus HS15 plus 2. As the HS15 performs self-check tests, the lights over the , and keys flash twice, and two CONT RUN SINGLE SWIVEL KNIFE additional beeps sound. 3. When the self-check tests are completed, the lights blink and the beep sounds three times.
  • Page 19: Add Plotters

    Installation 6. Click on Add. The added plotter appears in the Ready for Plotting plus list box. Your system is now set up to use the HS15 plotter. Note: The Default Plotter note in the lower right corner of the dialog box tells you the name of the plotter your jobs will be sent to unless otherwise specified in the Plot program.
  • Page 20: Delete Plotters

    plus HS15 Deleting Plotters To remove plotters from the system: 1. In the Ready for Plotting Box, click on the name of the plotter to be deleted. 2. Click on Delete. Assigning Default Plotter A default plotter can be assigned if more than one plotter is connected to GRAPHIX ADVANTAGE Note: There must be plotter names in the Ready for Plotting Box to select a default plotter.
  • Page 21: Materials And Tools

    The HS15 uses the same plotting materials as all Gerber plotters. Gerber vinyl products in high performance or intermediate grades are translucent, reflective, or metallic and come in a wide range of colors. Also available are direct cut silk screen, ruby photo film, paint masking material, rubber sandblast stencil material, and heat transfer materials.
  • Page 22: Idler Roller

    plus HS15 CAUTION: When power is on, the carriage spindle must be moved only by using the slew keys. Attempts to manually move the plotter drum, rotate or force the tool up or down may damage the plotter. CAUTION: While power is off, center the carriage by gently pushing toward the center of its travel.
  • Page 23 Materials and Tools All other materials can be fed over the idler roller, as shown below. To feed and align the material 1. Feed the material through the plotter as shown in the appropriate diagram, according to the type of material you are working with. 2.
  • Page 24: Helpful Hints

    plus HS15 HELPFUL HINTS When you change materials, open the bail arms and roll the material back onto the roll. Tape the ends securely to prevent the roll from unraveling. plus The HS15 plots so fast that heavy rolls of material such as reflective vinyl cannot turn as rapidly as the plotter tries to pull them.
  • Page 25: Tool Force Dial

    Materials and Tools Tool Force Dial The tool force dial on the front of the housing indicates the tool force setting and the amount of tool force, or pressure, that is applied to the tool during operation. This pressure ensures uniform cuts and pen lines. Tool force is adjusted by turning the small tool force knob on the end of the tool force housing, as shown in the illustration below.
  • Page 26: Adjustments

    Blade wear -- Increase tool force after several thousand cuts. Gerber recommends experimenting with tool force settings as well as plus keeping a logbook of the settings. Refer to the HS15 Tool Force Settings Reference Card for guidelines.
  • Page 27: Pen Holder And Pens

    Materials and Tools Pen Holder and Pens The pen holder is shipped with a black pen installed. After loading the plotting paper, install the pen holder in the carriage spindle as follows: To install the pen holder 1. Select the pen holder with pen installed from the tool rack attached to the rear cover.
  • Page 28: Pen Replacement

    PEN REPLACEMENT Spare pens in blue and red are included in the tool kit. Additional pens are available through your Gerber distributor. To replace a pen 1. Insert a flat-tip screwdriver into the notch at the base of the tool cap (see below).
  • Page 29 Materials and Tools 5. Push down on the upper end of the pen until the point just touches the table surface. 6. Use the Allen wrench to tighten the set screw near the tip of the pen. Do not over-tighten the set screw or the pen could be crushed. 7.
  • Page 30: Pounce Wheel Holder

    plus HS15 Pounce Wheel Holder Pouncing is a technique used to create an outline for a sign that will later be hand-painted. It can also be used for vinyl character alignment on a 15-inch plotter when the job is much longer. The pounce wheel is designed to pounce (perforate) holes either perfectly aligned or off- center to the direction of travel.
  • Page 31: Pounce Wheel Replacement

    Materials and Tools 2. A plastic lift washer is used to reduce friction between the tool and the lift fork of the carriage spindle during operation. There should be one installed on the pounce wheel holder. If not, slip a lift washer from the tool kit over the barrel and slide the washer to the top of the holder.
  • Page 32: Knife Holder And Blades

    HS15 Knife Holder and Blades Gerber blades are extremely wear-resistant. In testing, Gerber cut over 10,000 one-inch letters using a single blade before testing was discontinued with the blade still cutting satisfactorily. Other blade manufacturers have unsuccessfully attempted to duplicate this cutting plus precision and durability.
  • Page 33 Materials and Tools To install a knife holder 1. Load vinyl or other material. 2. Select the knife holder that matches the knife mode you want to use. 3. A plastic lift washer is used to reduce friction between the tool holder and the lift fork of the carriage spindle during operation.
  • Page 34 Controltac 180 Delux 210 Gold/Silver 30 ° Dusted Crystal 210 .05-1 HS-42° Florescent 210 Scotchcal 220 Translucent 230 GerberCal Gerber IP Plus GerberMask I & II 30° HS-42° Heat Transfer Flock Hot Split Plastisol Metalized Polyester Screen Print 30° HS-42°...
  • Page 35: Blade Replacement

    Extra blades and special angled blades for sandblast vinyls are available from your Gerber distributor. Replacement procedures for the tangential and swivel knife blades are different. To replace the tangential knife blade 1.
  • Page 36 plus HS15 To replace and adjust the swivel knife blade WARNING: Blades are sharp. Take care when installing a new blade. CAUTION: Do not handle the blade with other tools. It is fragile and subject to breakage if mishandled. 1. Remove the plastic adjustment shoe from the base of the tool holder by rotating it counterclockwise until it comes...
  • Page 37: Operation

    OPERATION Travel Limits plus Each time that you turn on the HS15 , the carriage moves to the keypad end of the plotter and touches the bumper. This tells the controller the plotter travel limits. The carriage then backs away from the bail arms to allow you to open the bail arms for material loading.
  • Page 38: Front Panel

    plus HS15 plus 5. The HS15 “homes” the carriage toward the keypad end of the plus machine. (The HS15 home position is at the keypad end of the plotter and the adjustable sprockets are at the opposite end.) Front Panel plus The HS15 front panel keys shown below are used to perform all of the...
  • Page 39: Slew Keys

    Operation SLEW KEYS Slew keys are the four keys surrounding the key. SLOW SLOW Press the left and right slew keys to unroll material before plotting, to position the tool for plotting, to position the carriage and material between jobs, and to rotate the drum and feed material through the plotter or back toward the roll holder.
  • Page 40: Swivel Knife Key

    Note: When doing demanding jobs where high accuracy is desired (such as Repeats, EDGE jobs), Gerber recommends that you use tangential knife mode rather than swivel knife mode. When swivel knife mode is selected, the light over the SWIVEL key is on.
  • Page 41: Init Knife Key

    Operation When cutting regular vinyl in tangential knife mode, try a tool force setting of .5. When cutting regular vinyl in swivel knife mode, set the tool force setting at .5 (too much pressure will cut through the material). Heavier material (such as reflective vinyl) requires increased tool force settings, no matter what mode.
  • Page 42: Run Single Key

    plus HS15 RUN SINGLE KEY to plot a single job. This plot mode allows the RUN SINGLE operator to reposition material between jobs and/or to pen plot using SINGLE paper before cutting vinyl. may be used with either swivel RUN SINGLE knife mode or tangential knife mode.
  • Page 43: Single Plot Exercise

    Operation Single Plot Exercise plus 1. Turn on the HS15 . Load plotting paper, install the pen and pen holder, and set the tool force to .5. 2. Using the slew keys, position the carriage spindle approximately 1" from the front edge of the plotting paper. Also, be sure that there are several inches of paper extending past the carriage spindle and to the left of the plotter.
  • Page 44: Controlled Stop

    plus HS15 Controlled Stop ) to stop plotting and check the RUN CONT RUN SINGLE current job. To stop a continuous mode plot plus 1. Press either Run key. The HS15 stops the plot at the next logical break in the program. Note: The slew keys may be pressed to maneuver the carriage or material.
  • Page 45: Reset Key

    Operation RESET KEY Use the key to stop plotter operation in case of emergency, to RESET clear error signals, and to access Special Diagnostics at power up. RESET To cause an emergency stop Press the key while a job is plotting. The following sequence RESET occurs: plus...
  • Page 47: Special Diagnostics

    Beeps indicate a communications error. (A loop back connector is needed for this test; see your Gerber distributor.) Wagon Wheel Test Plot − Press the left arrow key to access. Used to check X, Y, Z axes in plot mode and to verify operation after...
  • Page 48: Wagon Wheel Test Plot

    X08 Cut Test - Press the down arrow key to access. Use to test cut quality. Note: If the plotter consistently fails a special diagnostic, contact Gerber Field Service Department at 800-828-5406, or fax at 203-645- 2448. WAGON WHEEL TEST PLOT To plot the Wagon Wheel Test Plot Load plotting paper and install the pen holder.
  • Page 49: Square/Circle Test Plot

    3. Select swivel or tangential knife mode according to the knife holder loaded. 4. Press to plot once or to plot continuously. RUN SINGLE RUN CONT 5. Compare the test plot to the illustration below. If they do not look the same, call Gerber Field Service.
  • Page 50: X08 Cut Test

    2. Load vinyl and install the knife holder. 3. Press the down arrow key. 4. Press to plot once or to plot continuously. RUN SINGLE RUN CONT 5. Compare the test plot to the illustration below. If the plot is different, contact Gerber Field Service.
  • Page 51: Error Conditions

    ERROR CONDITIONS plus The HS15 is programmed to detect certain mechanical/electrical error conditions at power-up or during operation. When an error condition occurs, the plotter may turn off power to the servo motors. There will be continuous beeping and flashing lights. Error Signals There are three kinds of error signals: 3-second steady tone, lights on (running job)
  • Page 52: Determining Error Numbers

    plus HS15 DETERMINING ERROR NUMBERS The number of beeps and blinking lights signify the type of error that has occurred. Error conditions are assigned a 2-digit number. The number is displayed by flashing lights and beeping, one digit at a time. key displays the first (tens) digit;...
  • Page 53: Error Codes

    Theta motor encoder Call Gerber Field Service. failure Power relay off Try power up again or call Gerber Field Service. X axis error Call Gerber Field Service. Call Gerber Field Service Department at 800-828-5406 (in the USA), or fax at 203-645-2448.
  • Page 54 HS15 Error Number Error Description Operator Response Y axis error Call Gerber Field Service. Z axis error Call Gerber Field Service. Theta axis error Call Gerber Field Service. RS-232 test failure Call Gerber Field Service. Illegal plot data command Check plot data;...
  • Page 55: Maintenance

    MAINTENANCE This section includes instructions for routine cleaning and lubrication to plus keep the HS15 plotter in good working order. In addition, instructions for fuse replacement are included. Cleaning/Lubrication Routine cleaning and lubrication should be done monthly or after every 160 hours of use, whichever occurs first.
  • Page 56: Sprockets And Bail Arms

    plus HS15 2. Apply a light coat of oil to the rear way and front way. Apply with a lint-free cloth. 3. Tip the plotter on its left side. CAUTION: Do not rest the plotter on its right side. Do not use the way shaft to lift or turn the plotter.
  • Page 57: Fuse Replacement

    Maintenance 4. Place one drop of oil in each pin of the sliding sprocket at the front of the plotter, as the arrows below indicate. (The orientation of this picture is from standing in front of the plotter.) 5. Slide the sprocket back and forth to work the oil into the bushing. Oil the bail arm pins.
  • Page 58 plus HS15 4. Pull out the light gray fuse carrier. Note that the carrier has a white arrow on it pointing to the right (as do the two arrows on the black plastic plate). 5. Remove any blown fuse. Install a new fuse of the same type and rating (5-amp Slo-Blo) in the same place.
  • Page 59: Plotter Adjustments

    It also contains a brief description of plotter adjustment problems that should be handled by contacting Gerber Field Service (800-828-5406). Note: Gerber warranties do not cover unauthorized repair. Some service procedures require delicate adjustment of plotter parts. If...
  • Page 60: Troubleshooting Guide

    If the condition occurs in normal mode (see Reference), the X GRAPHIX ADVANTAGE Axis (backlash) needs adjustment. Call Gerber Field Service. If the condition occurs in the Axis Swap mode (see GRAPHIX ADVANTAGE Reference), the Y Axis (backlash) needs adjustment. Call Gerber Field Service.
  • Page 61: Replacing Boards

    If you need to change a board because of repair or update, refer to the diagram and listed parts below when you talk to Gerber Field Service. See the next page for the procedures to follow to access the board.
  • Page 62 HS15 To access the logic and control boards CAUTION: Do not attempt to access the logic and control boards without first contacting Gerber Field Service at 800-828-5406 for assistance. 1. Turn off power at the plotter. 2. Remove all screws from the right side panel (11) and slide the panel off.
  • Page 63: Plotter Adjustments

    Plotter Adjustments Plotter Adjustments When making plotter adjustments, refer to the diagram in the Appendix plus and the “HS15 Plotter Parts List” for part identification. The numbers in parentheses in the text refer to the numbers in the diagram. Z AXIS (TOOL HEIGHT) ADJUSTMENT Symptoms The tool does not touch the material or touches only between characters.
  • Page 64: Theta Axis (Tool Rotation) Adjustment

    8. Tighten the Phillips screw (32). Note: If a “half moon” is worn on the wedge (33), do not attempt any further modification. Call Gerber Field Service. THETA AXIS (TOOL ROTATION) ADJUSTMENT Symptoms Letters have jagged or serrated edges.
  • Page 65 8. Turn the machine on and watch the disk. It should rotate and stop between the opto-sensors (located under 65). If this does not occur, call Gerber Field Service. Otherwise, continue with the next step. 9. If the disk is clean and centered and homed correctly, loosen the Allen set screw (47) but DO NOT MOVE THE DISK.
  • Page 66: Axis Backlash Adjustment

    To adjust the mesh of the jackshaft gear with the Y motor pinion to produce good letter quality in Normal mode Adjustment Procedure Please call Gerber Field Service at 800-828-5406. You may find it helpful to refer to the plotter diagram in the Appendix while performing the adjustment procedure.
  • Page 67: Appendix

    APPENDIX plus This appendix contains diagrams of the interior and parts of the HS15 plotter. Gerber Field Service may refer you to this diagram to help you identify parts when you need to make plotter adjustments. The names of plus the parts are listed in the “HS15...
  • Page 68 plus HS15 Back of the chapter page...
  • Page 69 Appendix Fold out diagram of the interior of the HS15...
  • Page 70 plus HS15 Back of the fold out diagram...
  • Page 71: Hs15 Plotter Parts List

    Appendix plus HS15 Plotter Parts List Number Part Description Base & Side Plate Assy. Sensor Disk Cam Assy. Rear Way Grooved Drum Assy. Front Way Bearing Ball .375 x .875 x .281 Left Bail Arm Assy. Right Bail Arm Assy. Paper Bail &...
  • Page 72 plus HS15 plus HS15 Plotter Parts List Number Part Description Vert. Lift Tool Arm & Carr. Assy. Vert. Lift Carriage Vert. Lift Bearing Cap Screw 4-40 x .375 Button Head Spindle Assy. Spindle Belt Screw 4-40 x .312 PHH Lk Wash Adjusting Pad Tool Lifter Pivot Front Idler Pulley Assy.
  • Page 73 Appendix plus HS15 Plotter Parts List Number Part Description Drum Clamp .375 x .625 x .032 Spacer Retainer E-Ring Screw 4-40 x .438 Screw 8-32 x .375 Washer Lock #8 Washer Flat #8 Spring CPRSN .042 x .48 x .625 (Drum) Bail Arm Screw Ball Bushing Assy.
  • Page 74 plus HS15 plus HS15 Plotter Parts List Screw 6-32 x .375 Washer Lock #6 Washer Flat #6 Screw Special 12-24 x 0.500 Washer Flat 0.159 x 0.435 Screw 06-32 x 0.500 Tool Force Housing Assy. Screw 4-40 x .25 Screw M3 x .5-6g x 8mm Washer Lock #5 Left Side Cover Right Side Cover...
  • Page 75 plus HS15 REFERENCE CARD KEY/FUNCTION DESCRIPTION RUN SINGLE Key -- plus Plot Press to plot single jobs. The HS15 returns to the off-line status (as at RUN SINGLE power-up) after each job and waits for the operator to press key again to RUN SINGLE plot the next job.
  • Page 76 Heat Transfer Flock Hot Split Plastisol Metalized Polyester Screen Print 30° 42° Static Cling Sandblast 521 45° or 60° Sandblast 522 Pouncing paper 5-6 ( pounce wheel Plotting paper .5-1 ( Gerber Field Service Department 800-828-5406 Outside the USA please fax: 203-645-2448...
  • Page 77 Z motor encoder failure Call Gerber Field Service. Theta motor encoder failure Call Gerber Field Service. Power relay off Try power up again or call Gerber Field Service. X axis error Call Gerber Field Service. Y axis error Call Gerber Field Service.
  • Page 78 Allow plotter to cool down or move it to a cooler area. Call Gerber Field Service. Illegal interrupt error Try power up again. Call Gerber Field Service. Unknown interrupt error Try power up again. Call Gerber Field Service. Theta home error Try power up again.

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