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Gerber ODYSSEY XP Owner's Manual

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  • Page 1 Owner’s Guide...
  • Page 2 OMEGA, MacImprint, GERBER MAXX, Automatic Material Alignment, and GerberMag, are trademarks of Gerber Scientific Products, Inc. HPGL is a trademark of Hewlett-Packard Company. Scotchcal is a trademark of 3M Corporation. Windows is a registered trademark of Microsoft Corporation in the US and other countries.
  • Page 3 FCC NOTICE 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.

  • Page 5: Table Of Contents

    Making jobs fit..........................27 Aligning with printed images...................... 28 Chapter 4: Tool Settings ..................... 29 Using the ODYSSEY XP with Gerber software................. 29 Determining which rule set is used ..................... 30 Choosing the material ......................... 32 Setting the tool force........................33 Adjusting corners........................
  • Page 6 Chapter 5: Advanced Functions................42 Repeats............................42 Material pulldown........................43 Pouncing ............................. 45 Factory default settings....................... 48 Communications ......................... 51 Chapter 6: Troubleshooting..................54 Version number .......................... 54 Warning messages ........................55 Error messages..........................57 Common problems/solutions ...................... 62 Chapter 7: Maintenance ..................... 64 Cleaning............................

  • Page 7: Chapter 1: Introduction

    Chapter 1: Introduction Thank you for purchasing the Gerber ODYSSEY XP plotter, a state-of- the-art plotter designed for use with Gerber OMEGA and GRAPHIX ADVANTAGE (GA) software as well as other software using the HPGL command set. In addition to handling and cutting vinyl films and mask materials, the ODYSSEY XP is specially designed to cut jobs printed on the GERBER MAXX...

  • Page 8: In This Manual

    Running Jobs presents the procedures for using the ODYSSEY XP control panel for cutting, plotting, and pouncing single and multiple jobs. Tool Settings shows how to use either the plotter or Gerber OMEGA or GA software to choose tool settings. Advanced Functions describes functions beyond routine job cutting.

  • Page 9: Safety

    Ground yourself by touching any bare metal inside the plotter frame prior to handling electronic components. Customer support If you require assistance, please contact your Gerber distributor or contact the Gerber Field Service Department at: 800-828-5406 (USA and Canada) 860-643-1515 (International) 860-648-8376 (fax) e-mail: gsptech@gspinc.com...

  • Page 10: Chapter 2: Getting Started

    CHAPTER 2 Getting Started Chapter 2: Getting Started This chapter contains the steps you need to prepare the plotter for cutting: ♦ unpacking and setting up the plotter ♦ connecting the data and power cables ♦ turning on the plotter ♦...

  • Page 11: Turning On The Plotter

    ODYSSEY XP to the list of available plotters in the software. The addition makes the plotter available for cutting. If you are an OMEGA or GA user, follow the instructions in the Reference manual to add the ODYSSEY XP as the default plotter. If you are using non-Gerber...

  • Page 12: Loading Material

    Loading material The ODYSSEY XP cuts and plots a wide variety of vinyl film, masks, and papers. Always use Gerber-authorized materials for highest quality. CAUTION: Do not load the material with a tool installed in the tool holder. Loading material into the plotter with the tool installed can result in damage to the blade or the material.
  • Page 13 Mounting the roll on the plotter There are three material roll stops that should be installed on one of the two material rollers (instructions for installing them are in the ODYSSEY XP unpacking, assembling, and repacking instructions). The right edge of the one on the left (as you face the plotter from the rear) should be aligned with the alignment mark on the plotter platen.
  • Page 14 CHAPTER 2 Getting Started 4 Push the center stop against the right edge of the material roll, then tighten the stop set screw. (If you change the size of the material, you will need to change the position of this stop.) Loading the material into the plotter The material is driven through the plotter by the grit wheels (located in the platen) when it is trapped between the pinch and grit wheels.
  • Page 15 To help you locate and align the grit and pinch wheels, there is a measuring scale on the platen. Use the lower scale inch readings for material up to 25" wide. Use the upper scale inch readings for material more than 25" (64 cm) wide. When you slide the material width adjustment handle to set the grit wheels for the material width, both the left and center grit wheels move as a unit.
  • Page 16 CHAPTER 2 Getting Started 2 Push in and slide the material width adjustment handle to set the grit wheels for the material width. If you set the width to the actual material width, the scale provides a compensation so that the material properly extends 1/2"...
  • Page 17 7 Pull the pinch wheel lever toward the front to clamp the material between the grit and pinch wheels. 8 The control panel displays the following: SELECT MATERIAL TYPE Sheet Roll Press F1 or F3 9 Press either F1 (sheet) or F3 (roll) to select the material type. For information on using the F1, F2, F3, and F4 function keys, refer to “Learning the control panel”...

  • Page 18: Cutting Clear Material

    CHAPTER 2 Getting Started 5 If an error is detected, the display shows Reload Material. Sensors indicate improper loading To check and reload material 1 Make sure the material roll stops are in the correct position and that the roll hasn’t “walked” during the material alignment sequence. 2 Remove and reload the material.
  • Page 19 Any non-Gerber clear material with clear backing • Any non-Gerber paper 20-pound or less Gerber does not recommend using the ODYSSEY XP to cut screenprint films such as Rubylith. When you return to using other material, make sure you turn skew control back on (normal or short).

  • Page 20: Checking And Measuring The Available Cutting Area

    CHAPTER 2 Getting Started SKEW Skew Control: ON − − − − norm ENTER Key to Accept 4 Press Enter twice to return to the Main Menu. Checking and measuring the available cutting area After you load material, you can check and measure available cutting area dimensions.

  • Page 21: Installing Tools

    For information on changing and adjusting blades, see Chapter 4, “Tools and Tool Settings”. If you are using a Gerber target alignment tool to align the tool holder with printed registration marks on the material, refer to “Aligning with printed images“...

  • Page 22: Changing Knife Blades

    CHAPTER 2 Getting Started Groove Flange 4 Close the holder and secure it by turning the latch fastener clockwise. Changing knife blades Knife blades dull slightly over time. Blade wear is normal and always a gradual change. Adjusting tool settings, as described in Chapter 4, Tools and Tool Settings, can extend blade life.

  • Page 23: Adjusting Knife Blade Exposure

    In addition, you may need to change a knife blade if you use different materials. The following chart summarizes knife blade angles and material used. Blade angle Examples of material used with specific blades 30° Thin materials, such as Ulano and Autotype 45°...
  • Page 24 CHAPTER 2 Getting Started The blade holder has hash marks around it. The adjustment cap has a pointer, which lines up with the hash marks. One hash mark equals 0.001" (1 mil or 0.0254 mm). Tip: The autocut off feature might require more blade exposure than normal. To set the blade exposure 1 Hold the knife tool with the blade toward the ceiling.

  • Page 25: Chapter 3: Running Jobs

    Chapter 3: Running Jobs This chapter describes the control panel and its use and explains how to run jobs : ♦ learning the control panel ♦ running jobs ♦ pausing, restarting, and canceling jobs ♦ automatically cutting a job off the roll ♦...

  • Page 26: Learning The Control Panel

    CHAPTER 3 Running Jobs Learning the control panel The plotter control panel provides functional control and status displays. The control panel consists of: ♦ the message display ♦ four menu selection function keys (F1, F2, F3, F4) ♦ two control keys (ENTER and CANCEL) ♦...
  • Page 27 If one job is loaded CANCEL key clears the job from plotter memory. If several jobs are CANCEL clears one job at a time, loaded starting with the first one received. If a job is running CANCEL stops all plotter motion, ends the job, and clears it from plotter memory.

  • Page 28: Running Jobs

    CHAPTER 3 Running Jobs Job status Job Status in the bottom line of the display (when in the Main Menu) shows the status of the plotter. The function key choices depend on the Job status as shown in the table below. Job Status Plotter Status Possible Action...
  • Page 29 Job Status: Ready 6 Press F1, Start-Job, and verify that the correct material is loaded in the plotter. This display does not appear if the Plotter Prompts checkbox is not turned on in Gerber software. Job: PLT1474.plt Color: White Type: 220 Press F4 key - >...
  • Page 30 CHAPTER 3 Running Jobs After completing the job, the Job Status returns to No Job . If you have sent several jobs, the Job Status displays Ready and you will need to press F1, Start-Job, to plot each job. Running multiple jobs Multi mode lets you run several jobs without having to press Start-Job before each one.

  • Page 31: Pausing, Restarting, And Canceling Jobs

    Note: In Multi mode, the job/color/type display does not appear even if the Plotter Prompts check box is turned on in the Plotter Settings dialog box in the GAPlot32/GSPPlot program. Job Status displays Running and ## % DONE. (The percentage appears only with OMEGA or GA version 6.2 or higher.

  • Page 32: Automatically Cutting Off A Job

    CHAPTER 3 Running Jobs To pause a job and restart a job 1 To pause a job, press F1, Pause-Job. MAIN MENU Pause-Job Settings Mode: Single Job Status: Running 2 The current Job Status changes to Paused. To restart the job, press F1, Start-Job.

  • Page 33: Making Jobs Fit

    To automatically cut off a job 1 At the Main Menu, press both the left and right slew keys at the same time. (Press both keys quickly or the Main Menu will appear.) 2 Press the Enter key. 3 The carriage moves to the middle, then cuts left to the edge of the material.

  • Page 34: Aligning With Printed Images

    The ODYSSEY XP is specially designed to cut jobs printed on the GERBER MAXX. Before you print a design, select the check box to create targets [ ] on the printout. Targets are used with a target alignment tool to provide easier alignment of the knife.

  • Page 35: Chapter 4: Tool Settings

    Using the ODYSSEY XP with Gerber software The ODYSSEY XP can be completely controlled with OMEGA or GA version 6.2 (and higher) by using controls in the Plotter Settings dialog box. This dialog box is explained in Gerber software Reference manual.

  • Page 36: Determining Which Rule Set Is Used

    Determining which rule set is used If the Use Settings check box is turned on in Gerber software, the rule set for the displayed material is sent to the plotter. A Gerber software rule set is used unless the plotter is manually set to ignore the software rule set.
  • Page 37 If the Use Settings check box is turned off in Gerber software, the rule set in the ODYSSEY XP control panel is used. Rule set selection in the ODYSSEY XP can ignore the rule set included with the job. This condition is used for spool files, which can have embedded rules.

  • Page 38: Choosing The Material

    Plotter Settings dialog box in GAPlot32/GSPPlot. Choosing the material Material can be chosen in Gerber software at the time of job design or in the plot program. Refer to the Reference manual when making a material choice in the software. Material choice can also be set or changed at the plotter using the control panel.

  • Page 39: Setting The Tool Force

    Auto cutoff tool force is preset and is not affected by changes to tool force settings. Observe the following rules: ♦ Tool settings sent from Gerber software overrides plotter tool settings during a job unless this feature is turned off either in Gerber software or in the plotter.
  • Page 40 ♦ Heavier material, such as reflective vinyl, requires increased tool force. To make changes in Gerber software Open the Plotter Settings dialog box in GAPlot32/GSPPlot and use the slide control to make the force change.
  • Page 41 In the example below, F3 has been pressed five times to increase the tool force for the selected material by five clicks. ADJUST TOOL FORCE - less more + ..ENTER Key to Accept ♦...

  • Page 42: Adjusting Corners

    CHAPTER 4 Tool Settings 4 Press F3 to increase the force or F4 to decrease it. The maximum setting is 16 ounces in 0.5 ounce steps. ENTER TOOL FORCE Force 3.5 oz. ENTER Key to Accept 5 Press ENTER to accept the value and return to the Current Settings menu.
  • Page 43 There are three ways to change the corners ♦ the first way is to make the choice in Gerber software ♦ the second way is to make quick, incremental changes at the plotter control panel (like changing the darkness on a copy machine) ♦...
  • Page 44 CHAPTER 4 Tool Settings 2 On the Settings menu, press F1 Default, to use the present tool settings for the select material. Press F2, Corners, to change the setting. (Scotchcal 220 is shown as an example. Corners change applies to the material shown in the menu.) 3 Press the F1 or F2 key to decrease the corner sharpness, or press the F3 or F4 key to increase the corner sharpness.

  • Page 45: Setting The Speed

    Higher speeds are used for shorter jobs, such as those under 10 feet. There are two ways to change the speed ♦ the first way is to make the choice in Gerber software ♦ the second way is to make specific numeric changes at the plotter...

  • Page 46: Setting Acceleration

    There are two ways to change the acceleration ♦ the first way is to make the choice in Gerber software ♦ the second way is to make specific numeric changes at the plotter control panel...
  • Page 47 To adjust acceleration at the plotter control panel 1 Press F3 while holding down the ENTER key for the Operational Setup menu. OPERATIONAL SETUP Settings System Misc. ENTER for Main Menu 2 Press F1, Settings, to get the Current Settings menu. CURRENT SETTINGS Speed Force...

  • Page 48: Chapter 5: Advanced Functions

    CHAPTER 5 Advanced Functions Chapter 5: Advanced Functions Previous chapters presented information on basic ODYSSEY XP plotter operations such as loading material, installing tools, running a job, and choosing tool settings. This chapter provides information about additional ODYSSEY XP functions including: ♦...

  • Page 49: Material Pulldown

    To repeat a job 1 From the Main Menu, press F3 while holding down the ENTER key. The Operational Setup menu appears. 2 Press F4, Misc. OPERATIONAL SETUP Settings System Misc. ENTER for Main Menu 3 Press F1, Repeats. MISC SETTINGS Repeats Pounce Pulldown...
  • Page 50 CHAPTER 5 Advanced Functions Pulldown occurs as needed and will vary based on the shapes in the job, the amount of material already pulled down, and a user-set minimum pulldown length. User choices for minimum pulldown are 4", 8", 12", 24", 32", or 48"...

  • Page 51: Pouncing

    Pouncing creates a perforated graphic outline on paper. Instead of cutting or drawing, pouncing punches holes in material with a special Gerber tool, which is purchased separately. The optional pounce tool looks like an awl or a sewing needle. It is driven down into the paper to make a series of small holes.
  • Page 52 Material speed and tool force for white paper are set for normal running. Increase the tool force to 10 ounces. If you are using software other than Gerber software, refer to your third- party software manual or select pounce at the ODYSSEY XP keypad.
  • Page 53 7 Choose the material you want to pounce. 8 Increase the tool force to 10 ounces, which is 62.50 percent. 9 Click the Cut/Pounce icon to send the job to the plotter. To select pounce from the ODYSSEY XP control panel 1 Attach the pounce cutting strip.

  • Page 54: Factory Default Settings

    CHAPTER 5 Advanced Functions Turning off pounce Pounce remains in effect until it is turned off. Turning the plotter off and back on does NOT turn off pounce. Follow the procedure below to turn off pouncing before sending a cut or plot job to the plotter. Tip: Use a piece of vinyl carrier to store the pounce strip and keep it clean for future re-use.
  • Page 55 Reloading factory defaults for the current material Use the following procedure to restore the default settings for the currently selected material only. To reload factory defaults for the current material 1 On the Main menu, press F3 for the Settings menu. 2 On the Settings menu, press F3, Material.
  • Page 56 CHAPTER 5 Advanced Functions Reloading factory defaults for all materials Materials are reset to default settings for that material. Custom materials are reset to Scotchcal 220 settings. To reload factory defaults 1 Press F3 while holding down the ENTER key for the Operational Setup menu.

  • Page 57: Communications

    Communication settings Baud Data Stop Parity 57600 None System settings Label Value Scotchcal 220 material Selected HPGL units 0.01 mm/unit Pounce Type Pulldown 24" (61 cm) Run mode Single Text Display English Use rule sets Communications The communication settings on your computer and plotter must match. Plotter settings are preset at the factory to communicate with OMEGA and GRAPHIX ADVANTAGE.

  • Page 58: Communication Settings

    CHAPTER 5 Advanced Functions Communication settings To change the communication settings for the ODYSSEY XP. 1 Press F3 while holding down the ENTER key for the Operational Setup menu. 2 Press F3, System to get the System Parameters menu. OPERATIONAL SETUP Settings System Misc.
  • Page 59 6 For Baud Rate, press F3 or F4 to change the setting, then press ENTER to accept. ENTER BAUD RATE Baud 57.6K ENTER Key to Accept 7 For number of Stop Bits, press F3 and F4 to change the setting, then press ENTER to accept.

  • Page 60: Chapter 6: Troubleshooting

    CHAPTER 6 Troubleshooting Chapter 6: Troubleshooting Your ODYSSEY XP plotter will provide you with trouble-free operation and productivity for many years to come. However, if you experience an unexpected or unusual sequence of events, use this section to address: ♦ Version number ♦...

  • Page 61: Warning Messages

    5 The Version number appears. Your Gerber Field Service representative can interpret it for you. Note: This display is shown as an example only. The display on your plotter might be different. ODYSSEY XP C.3/D.2/C.0/C * No Foreign Language S/N: C019123456...
  • Page 62 CHAPTER 6 Troubleshooting If you turn off the plotter, affected settings return to the default. You will have to re-enter changes to the affected settings. Job clipped If a job extends beyond the X or Y axis boundaries, it is too large for the plotter and displays a Job clipped message during the run of the job.

  • Page 63: Error Messages

    When an error condition occurs, the plotter may turn off power to the motors. If you require assistance, please contact your Gerber distributor or contact the Gerber Field Service Department at: 800-828-5406 (USA and Canada)
  • Page 64 CHAPTER 6 Troubleshooting Error example 1 The first example of an error message is shown below. Pressing F2 restarts the internal plotter system. If the message reappears, consult the Error Codes table, which begins on the next page. Look up the system error number and perform the correction listed.
  • Page 65 Error codes The control panel displays System Error followed by an error code number. The error code numbers and their meanings are listed in the table below. Error / Failure Meaning Correction Read-Only Memory is Contact Field Service. damaged. Random-Access Contact Field Service.
  • Page 66 CHAPTER 6 Troubleshooting Error / Failure Meaning Correction Z axis power, Check Z axis encoder Contact Field Service. encoder or wiring and power connectors. failure X axis encoder Check X axis encoder Contact Field Service. failure connector. X2 axis encoder Check X2 axis encoder Contact Field Service.
  • Page 67 Error / Failure Meaning Correction EEPROM failure Firmware memory chip Restore factory defaults. not functioning. Turn off power. While holding down F1 and CANCEL keys, turn on power. Retry. Call Field Service if retry fails. X axis overload Motion along axis is Clear the jam.

  • Page 68: Common Problems/Solutions

    CHAPTER 6 Troubleshooting Common problems/solutions This chart of symptoms can help identify the possible problem and the recommended adjustment procedure. Refer to the table below for help when solving a problem. Note: Symptoms listed in bold is the message displayed on the control panel. Symptom Recommended Procedure Reload Material.
  • Page 69 Symptom Recommended Procedure Pinch Wheel Error Pinch wheels are in the wrong position. Slide grit Pinch wheel too far wheels and pinch wheels to place one pinch wheel from material edge one-half inch from material edge. Pinch wheels are up Move pinch wheel lever to lower the pinch wheels.

  • Page 70: Chapter 7: Maintenance

    CHAPTER 7 Maintenance Chapter 7: Maintenance This section covers cleaning, routine maintenance, and fuse replacement. Cleaning Routine cleaning should be done weekly or after every 80 hours of use, whichever occurs first. Use a clean, lint-free cloth and 97% or greater isopropyl alcohol to clean dust and debris.
  • Page 71 To clean grit wheels 1 Pull back the pinch wheel lever. 2 Remove the pin that secures the left pinch wheel assembly (when viewed from the rear of the plotter. Pinch wheel Pin securing pinch assembly wheel assembly 3 Move all three pinch wheels away from the grit wheels. 4 Brush each grit wheel at 45°...
  • Page 72 CHAPTER 7 Maintenance Carriage To clean the carriage 1 Remove any tool installed in the tool head 2 With canned air, gently blow clean the carriage to remove paper dust. Spray air Edge sensors Use the Clean? menu function to determine if sensors need to be cleaned. To determine if the sensors need to be cleaned 1 Remove all material from the plotter.
  • Page 73 6 If dust or debris is detected ( Dust/Object Detected ) in an edge sensor <Front> <Back> ), properly clean as described below. 7 If dust or debris is detected in any of the other sensors, used canned air to gently blow air through the sensor to remove dust. 8 If the sensors are clean, press ENTER twice to return to the Main Menu.
  • Page 74 CHAPTER 7 Maintenance Tip: Spraying canned air between the edge sensor and the plotter will help the lens to dry. 5 After the edge sensor is dry, turn on power to the plotter. Y axis beam and tool assembly Dirt on the metal ways can shorten the life of moving parts and adversely affect cutting quality.

  • Page 75: Cut Strip Replacement

    Cut strip replacement Replacement strips can be purchased from your distributor. Follow the procedures below to replace the cut strip. To replace the cut strip 1 Remove the worn cut strip by lifting it up at one end and pulling it straight up together with the underlying adhesive.

  • Page 76: Ac Fuse Replacement

    CHAPTER 7 Maintenance AC fuse replacement WARNING: Turn off the power switch and disconnect the power cord from the power supply. The fuse is located in the AC power connector on the rear panel where the power cord plugs into the unit. When this fuse is blown there is no power supplied to the plotter, nothing appears in the display area, and the fan is off.

  • Page 77: Chapter 8: Hpgl Support

    Chapter 8: HPGL Support This chapter contains information on Hewlett-Packard Graphics Language (HPGL) commands supported by the ODYSSEY XP plotter. These supported commands are used by selected third-party software vendors to operate the ODYSSEY XP plotter. For specific information on third-party software, contact the vendor of that software.
  • Page 78 CHAPTER 8 HPGL support OS - Output Status of plotter. Responds with one DECIMAL number whose hexadecimal bit pattern is: Condition Value Tool is up Tool is down the first OS; command received since the previous IN; command any other ERROR exists PA - Pen Absolute coordinates PR - Pen Relative coordinates...

  • Page 79: Hpgl Test File

    HPGL test file The following procedures let you create and plot a one-inch box and test that your system is communicating with the ODYSSEY XP plotter. To create a test file 1 Use a plain text editor, such as Notepad, and create the following text. A semicolon after the PG must be the last character in the file.

  • Page 80: Changing The Hpgl Units

    CHAPTER 8 HPGL support Changing the HPGL units The ODYSSEY XP is factory set with an HPGL unit of 0.010 mm (0.0003937"). To change it to 0.025 mm (0.0009843"), follow this procedure. To change the HPGL units 1 Press F3 while holding down the ENTER key for the Operational Setup menu.

  • Page 81: Appendix: Specifications

    Appendix: Specifications Material Width 4"-52" (127.0 mm-1321 mm) Cutting Width up to 49" (1244.6mm) Max. Media Thickness 0.045" (1.1mm) Driving Mechanism GerberDrive Knife/Cut Type/Principle Swivel Mechanical Resolution 0.0002" (0.005mm)** Number of Pressure Rollers Knives 30 /45 /60 Offset 0.02 inches Pens HP Compatible Max Cutting Speed (Axial)

  • Page 82: Index

    65 cleaning, 61, 66 figure of, 15 skew control, 13 Changing blade, 16 EEPROM error, 54, 61 Check box, GA E-mail to Gerber, 56 Use Settings, 29 Enter key, 19 Clamp, tool, 15 Error code, 58–60 Cleaning Error messages, 56...
  • Page 83 Function keys, 19 Fuse, replacing, 69 Loading material, 6–14 GA (GRAPHIX ADVANTAGE) pounce, 45 Main Menu, 5 using with the plotter, 28 Maintenance, 63 Grit wheels Material cleaning, 63 clear, 12 correct placement, 8 how to load, 6–14 pinch wheel error, 62 pulldown, 42 selecting, 31 Material pulldown, 42...
  • Page 84 INDEX advance functions, 41 Single mode, 21 default settings, 47, 49 Slew keys, 20 fine tuning, 28 Slewing during paused job, 24 firmware version, 53–54 Software material pulldown, 42 plotter setup, 5 pouncing, 44 Speed, 38 troubleshooting, 53–62 Stalled, 21 using with GA, 28 Starting a job, 21 Plotter Settings dialog box, 28...

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