s91 Operator Manual

S-91 GERBERcutter
OPERATOR AND MAINTENANCE MANUAL
Copyright 1998 by Gerber Garment Technology, Inc. All rights reserved. This document may not be reproduced by any means, in whole or in part, without the written permission of the copyright owner. This document is part of the proprietary articles furnished to document Gerber Garment Technologys S91 GERBERcutter. In consideration of the furnishing of the information contained in this document, the party to whom it is given assumes its control and custody and agrees to the following: 1. The information contained herein is given in confidence and any part thereof shall not be copied or reproduced without the written consent of Gerber Garment Technology, Inc. 2. This document or the contents herein under no circumstances shall be used in the manufacture or reproduction of the article shown and the delivery shall not constitute any right or license to do so. The information contained in this document is subject to change without notice. Gerber Garment Technology, Inc., its subsidiaries and affiliates shall not be liable for errors in this documentation or for incidental or consequential damages in connection with furnishing, or use of this material. COMMAND, G (stylized logo), GGT, GERBER BRISTLE SQUARE, GERBERcutter, GERBERmover, Knife Intelligence, and MARKAMATIC are registered trademarks of Gerber Garment Technology, Inc. AccuMark, AccuPlot, Booster PAK, GERBERmarker, GERBERplanner, GERBERsaver, GERBERspreader, IMPACT, MicroMark, and POWER Processor are trademarks of Gerber Garment Technology, Inc. Windows NT is a registered trademark of Microsoft Corporation. Baldor is a registered trademark of Baldor Electric Company Spencer is a registered trademark of Spencer Turbine Company Other company names, brand names, and product names mentioned in this book are recognized as trademarks or registered trademarks of their respective companies. Gerber Garment Technology, Inc. 24 Industrial Park Road West Tolland, CT 06084 USA Printed in USA 2/98 Document Number 083878000
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Whats Inside ............................................................................................................................................. ix Conventions .............................................................................................................................................x Product Support ..................................................................................................................................... xi Safety Precautions.................................................................................................................................... xiii
1 S91 GERBERcutters
Available Models ........................................................................................................................................ 1 Traveling Conveyorized (TCW) ............................................................................................................. 1 Static ....................................................................................................................................................... 2 Zoned Valve Conveyor (ZVC)................................................................................................................ 2 Major Subsystems ....................................................................................................................................... 3 C200 Controller ...................................................................................................................................... 3 Cutting Table .......................................................................................................................................... 3 Cutter Head and Beam Assembly........................................................................................................ 4 Work Surface ...................................................................................................................................... 5 Vacuum Assembly .............................................................................................................................. 6 Limit Switches .................................................................................................................................... 7 Operator Controls ................................................................................................................................... 7 Emergency Stop .................................................................................................................................. 8 Circuit Breakers ................................................................................................................................ 10 Platform and Conveyor Controls....................................................................................................... 11 Beam Control Panel .......................................................................................................................... 13 Operator Workstation............................................................................................................................ 15 Options.................................................................................................................................................. 16 Spare Cutter Head (Without Covers) ................................................................................................ 16 Spare Sharpener Assembly................................................................................................................ 16 Right Side Option.............................................................................................................................. 17 Electric Drills .................................................................................................................................... 17 CTOT................................................................................................................................................ 17 Cutter Info Database (CIDB) ............................................................................................................ 18 POWER Processor ............................................................................................................................ 18
2 Basic Concepts
Direction and Location.............................................................................................................................. 19 Ends and Sides ...................................................................................................................................... 19 X, Y, and CAxes ................................................................................................................................. 20 Origin ........................................................................................................................................................ 21 Bite Feeding.............................................................................................................................................. 23 Software and Files..................................................................................................................................... 25 Software ................................................................................................................................................ 25 Cut File ................................................................................................................................................. 25 Setup ..................................................................................................................................................... 25
3 Cutting Markers
Spreading Material.................................................................................................................................... 28 Basic Cutting............................................................................................................................................. 29 Turning on the Cutter............................................................................................................................ 30 Enabling Servo Power........................................................................................................................... 31 Initializing the Cutter ............................................................................................................................ 32 Positioning the First Bite....................................................................................................................... 33 On TCW and ZVC Systems .............................................................................................................. 33
iii
On Static Systems.............................................................................................................................. 33 Selecting a Setup ................................................................................................................................... 35 Opening a Marker.................................................................................................................................. 36 Turning on the Vacuum......................................................................................................................... 37 Turning on the Laser Light.................................................................................................................... 37 Setting the Marker Origin...................................................................................................................... 38 Selecting Cutting Speed ........................................................................................................................ 39 Turning on the Knife Motor .................................................................................................................. 39 Processing a Marker .............................................................................................................................. 40 Exiting the Program............................................................................................................................... 41 Beyond the Basics ..................................................................................................................................... 42 Using Fabric Alignment ........................................................................................................................ 42 Using Pause Between Bites ................................................................................................................... 43 Using Check Origin............................................................................................................................... 43 Using X Data Scale Factor, Y Data Scale Factor .................................................................................. 44 Using Move To Origin .......................................................................................................................... 44 Using Trim Cut...................................................................................................................................... 45 Recovery from Interrupted Cutting ........................................................................................................... 46 Before Using Recovery Commands .................................................................................................. 46 Using Restore State ............................................................................................................................... 47 Restoring State Manually .................................................................................................................. 48 Using Piece Search................................................................................................................................ 49 Using Piece Recut ................................................................................................................................. 49 Using Restore Origin............................................................................................................................. 50 Using Bite Search.................................................................................................................................. 50
4 Utilities
Parameter Manager ................................................................................................................................... 52 Access Levels by Password................................................................................................................... 52 Parameters and Categories .................................................................................................................... 52 Run Time Biting........................................................................................................................................ 54 Static Length Biting............................................................................................................................... 54 Variable Length Biting.......................................................................................................................... 54 PreProcessor.............................................................................................................................................. 55 Reorder.................................................................................................................................................. 55 Common Line........................................................................................................................................ 55 Path Optimization.................................................................................................................................. 55 View Marker ............................................................................................................................................. 56 Selecting Pieces..................................................................................................................................... 56 Tool Code Reference......................................................................................................................... 56 Playing Back a Marker .......................................................................................................................... 56 Animate ............................................................................................................................................. 56 Piece by Piece ................................................................................................................................... 56 Segment by Segment ......................................................................................................................... 56 Queue Manager ......................................................................................................................................... 57 Job Queues ............................................................................................................................................ 57 Defaults for Queue Manager ................................................................................................................. 57 File Manager ............................................................................................................................................. 58 Directories and Files.............................................................................................................................. 58 Using Paths to Locate Files ............................................................................................................... 58 Using Wild Cards to Locate Files ..................................................................................................... 59 Locking File Manager ........................................................................................................................... 59 Cutter Information Database (CIDB) ........................................................................................................ 60
iv
Marker Report Types ............................................................................................................................ 60 Partial Marker Report ....................................................................................................................... 60 Marker Reports ................................................................................................................................. 61 Shift Reports ..................................................................................................................................... 61
5 Optimizing Cutter Performance

Sharpening and Replacing the Knife......................................................................................................... 63 Automatic Sharpening........................................................................................................................... 64 Sharpening When the Cutter is Idle ...................................................................................................... 64 Resetting for New Knife ....................................................................................................................... 65 Setting Knife Speeds............................................................................................................................. 66 Using Knife Intelligence ........................................................................................................................... 67 KI Settings ............................................................................................................................................ 67 Nulling Knife Intelligence Sensor......................................................................................................... 67 Using Path Intelligence ............................................................................................................................. 69 Path Intelligence Diagnostics ................................................................................................................ 69 Controlling Vacuum Levels ...................................................................................................................... 70 Energy Savings Mode ........................................................................................................................... 70
6 Maintenance
Safety Precautions............................................................................................................................. 72 Maintenance Procedures ........................................................................................................................... 73 Basics ................................................................................................................................................ 73 Advanced .......................................................................................................................................... 73 Electrical ........................................................................................................................................... 73 General Maintenance ............................................................................................................................ 74 Cleaning ............................................................................................................................................ 74 Lubrication........................................................................................................................................ 74 Ordering Spare Parts ............................................................................................................................. 74 Tools Available from GGT ................................................................................................................... 75 Additional Tools ............................................................................................................................... 75 S91 TCW Illustrations .......................................................................................................................... 76 S91 Static Illustrations .......................................................................................................................... 77 S91 ZVC Illustrations ........................................................................................................................... 77 Maintenance Summary and Schedule........................................................................................................ 79 8 Hour Maintenance Schedule .............................................................................................................. 79 40 Hour Maintenance Schedule ............................................................................................................ 85 160 Hour Maintenance Schedule .......................................................................................................... 91 960 Hour Maintenance Schedule .......................................................................................................... 97 Cutter Head ............................................................................................................................................. 103 Cover................................................................................................................................................... 103 Knife Drive Train................................................................................................................................ 104 Knife ................................................................................................................................................... 106 Sharpener Assembly............................................................................................................................ 107 Knife Guides and Offset...................................................................................................................... 109 Knife Guides ................................................................................................................................... 109 Knife Offset..................................................................................................................................... 110 Elevator............................................................................................................................................... 112 Elevator Guide Rods ....................................................................................................................... 112 Air Cylinder Rod............................................................................................................................. 112 Head Stops ...................................................................................................................................... 112 Caxis Drive ....................................................................................................................................... 113 Servo Gear ...................................................................................................................................... 113 Drive Belt........................................................................................................................................ 113
Knife Drive.......................................................................................................................................... 113 Tension and Pivot Arm Oil Cups .................................................................................................... 113 Knife Drive Gearing and Belts ........................................................................................................ 114 Knife Drive Motor........................................................................................................................... 115 Knife Speed..................................................................................................................................... 115 Electric Drill............................................................................................................................................ 116 Drill Bit ............................................................................................................................................... 116 Drill Assembly .................................................................................................................................... 118 Air Cylinder..................................................................................................................................... 118 Drive Belt ........................................................................................................................................ 118 Drive Motor..................................................................................................................................... 119 Drill Speed ...................................................................................................................................... 119 Beam ....................................................................................................................................................... 121 Roundway and Squareway .................................................................................................................. 121 Covers ................................................................................................................................................. 122 Basic Xaxis and Yaxis..................................................................................................................... 122 Servo Motor Gearing....................................................................................................................... 123 Servo Pinion Gearing and Torque Tube Belts................................................................................. 123 Yaxis Countershaft Gear ............................................................................................................... 124 Wheel Housing Cam Rollers ........................................................................................................... 125 Wheel Assemblies ........................................................................................................................... 125 Bite Encoder.................................................................................................................................... 125 Advanced Xaxis and Yaxis ............................................................................................................. 126 Roundway Bearings......................................................................................................................... 126 Squareway Bearings ........................................................................................................................ 126 Spring Scale Tests ........................................................................................................................... 127 Yaxis Drive Belt Tension .............................................................................................................. 128 Squaring the Beam .......................................................................................................................... 129 Table ....................................................................................................................................................... 130 Work Surface ...................................................................................................................................... 130 Work Surface Cleaner ......................................................................................................................... 132 Gear Box ......................................................................................................................................... 132 Pillow Block Bearings..................................................................................................................... 132 Roundways and Racks......................................................................................................................... 133 Roundways ...................................................................................................................................... 133 Racks ............................................................................................................................................... 133 Filters .................................................................................................................................................. 134 Vacuum Filter.................................................................................................................................. 134 Stack Filter ...................................................................................................................................... 134 Air/Reducer Filter ........................................................................................................................... 135 Vacuum Assembly............................................................................................................................... 135 Cover............................................................................................................................................... 135 Motor and Generator ....................................................................................................................... 136 Drive Belt Tensioning ..................................................................................................................... 136 Coupling Alignment ........................................................................................................................ 137 Material Handling Systems ................................................................................................................. 138 Clamp Bar ....................................................................................................................................... 138 Resealer ........................................................................................................................................... 138 Conveyor Drive Gear Box............................................................................................................... 139 Conveyor Drive ............................................................................................................................... 139 Lay Puller Gear Box........................................................................................................................ 139 Lay Puller Drive .............................................................................................................................. 140 Platform............................................................................................................................................... 141
vi
7 Troubleshooting
Product Support .............................................................................................................................. 143 Error Messages ....................................................................................................................................... 144 Class 1 FEP Errors.............................................................................................................................. 145 Class 1 MCC Errors ............................................................................................................................ 146 Class 2 Errors...................................................................................................................................... 147 Class 3 Errors...................................................................................................................................... 148 Class 4 Errors...................................................................................................................................... 148 Diagnostics.............................................................................................................................................. 149 Selecting Diagnostics ...................................................................................................................... 151 Input Output Test (DG 23).................................................................................................................. 151 KI Calibration (DG 20)....................................................................................................................... 152 C Home to System Zero Diagnostic.................................................................................................... 154 Cut Tests ............................................................................................................................................. 155 Beam Square Test ............................................................................................................................... 156 Heel to Heel Test ................................................................................................................................ 157 Knife Offset Setup .............................................................................................................................. 158 Training (CBT) ....................................................................................................................................... 159 Service Parts ........................................................................................................................................... 159 CAM Applications .................................................................................................................................. 160 Automated Cutting Concepts .............................................................................................................. 160 Data Preparation ............................................................................................................................. 161 Vacuum Hold Down ....................................................................................................................... 162 Knife Sharpening ............................................................................................................................ 162 Motion Control................................................................................................................................ 162
Glossary ............................................................................................................163 Appendix ...........................................................................................................169
vii
viii
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This manual contains information on using the S91 GERBERcutter. It includes the following chapters: Safety Precautions This introductory chapter details safety precautions you must follow when operating the S91 GERBERcutter. Read this section before you start cutting. Chapter 1 S91 GERBERcutters This chapter provides an overview of the three models of S91 GERBERcutters, including major components and optional equipment. Chapter 2 Basic Concepts This chapter discusses basic ideas you need to understand in order to use this automated cutting system. Chapter 3 Cutting Markers This chapter describes the basic steps required to start up the system, cut a marker or cut file, and shut down the system. Recovery procedures are also covered. Chapter 4 Utilities This chapter introduces utilities in the C200MT program that help you manage cut files and utilize the multitasking capabilities of the program. Chapter 5 Optimizing Cutter Performance This chapter covers how to quickly access settings in the C200MT program that optimize GERBERcutter performance for the current cut file. Chapter 6 Maintenance This chapter covers preventative and corrective maintenance procedures for S91 GERBERcutters. Included are maintenance schedules of procedures that GGT recommends be performed regularly after 8, 40, 160, and 960 hours of operation.
Whats Inside ix
Chapter 7 Troubleshooting This chapter suggests several ways to obtain help if you ever experience GERBERcutter performance that is less than expected. Error messages, diagnostics, and other support and application information are covered briefly. Glossary The Glossary lists terms you need to know. Index The Index provides an alphabetical listing of topics of interest in this manual.
Conventions
The following conventions are used throughout this manual: Bold type highlights important information in the text. Italic type highlights titles of other manuals.
Note:
Notes contain important or helpful information. Cautions appear before procedures that could cause damage to equipment or material if you do not do them correctly.
CAUTION:
WARNING!
Warnings tell you when you must follow a specific procedure or practice to avoid personal injury or death.
x Whats Inside
Product Support
As a part of our commitment to excellence, GGT provides complete product support for GERBERcutters, worldwide. Inside the United States and Canada For product support within the United States or Canada, call: 1-800-999-1448 For information about training or other products, call the GGT Sales and Service Office in your area. Have the following information ready when you call: Identify what equipment you are using. Identify any special equipment or software you are using, such as the drill option. Identify what software packages you are using. Include the software version numbers.
Outside the United States and Canada For software/hardware support, training, or information about products outside of the United States and Canada, call your local GGT Sales and Service office.
Whats Inside xi
xii Whats Inside
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About This Section
This section details safety precautions you must follow when operating the S91 GERBERcutter.
WARNING!
Failure to follow these safety precautions could result in injury or death.
Dangerous Procedure Warnings

Warnings precede potentially dangerous procedures throughout this manual. Instructions contained in warnings must be followed. You also should employ all other safety precautions that you deem necessary for safe operation of the equipment in your operating environment. Do Not Perform Maintenance Alone Do not perform any maintenance on the equipment unless another person that can render first aid and resuscitation is present. Live Circuits High voltages exist inside the C200 controller/vacuum electronics enclosure. Never perform any work inside the vacuum electronics enclosure. There are no operatorserviceable parts. Two power cables enter this enclosure: a three phase cable for the vacuum generator system and a singlephase power cable for the C200 controller. Both power cables must be disconnected before it is safe to work within the enclosure. There must be a main disconnect that meets local electrical codes for each power supply.
Safety Precautions xiii
Turn Off Power Before Maintenance To prevent accidental startup, always turn off all power by shutting off circuit breaker 1 before doing any maintenance.
Circuit Breaker 1
Laser Origin Light The origin light in the cutter head uses a laser light that points toward the cutting surface. When viewed as intended (by looking at the dot projected on the material to be cut), the laser should pose no hazard to operators. However, the origin light is a Class IIIa laser product, with a peak power of 5 mW at a wavelength of 670 nm. Never look straight into the light source of this laser beam; doing so may cause temporary, or even permanent, damage to your eyes. Direct, bright reflections from the laser may also be harmful. Remove all highlyreflective material (such as jewelry and mirrors) from the cutting surface before turning on the origin light. Turn off the origin light before performing any maintenance on the GERBERcutter.
WARNING!
Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.
xiv Safety Precautions
Moving Machinery Keep hands away from the Resealer and other moving machine parts to avoid personal injury. Make sure there is no one else near the table when you are operating the GERBERcutter. Replacing Parts Report any broken or missing parts to your Field Service representative. Because of the danger of introducing additional hazards, do not install substitute parts or perform any unauthorized modification of the equipment. Knife Blade The knife blade is very sharp. Be extremely careful when working near the knife blade. Clothing Loosefitting clothing, dangling neck chains and ties, loose jewelry, and long hair can be a hazard when working around machinery. Compressed Air Always use caution when using compressed air. Never use compressed air to blow lint and dust off clothing or skin. Lint Avoid breathing in lint when changing the table and stack filters. Wear a mask suitable for this purpose.
Safety Precautions xv
Equipment Training Never attempt to operate this machinery unless you have received formal training to do so. Do Not Operate in an Explosive Atmosphere Use extreme caution when handling flammable liquids such as cleaning solvents. Do not operate the equipment in the presence of flammable gases or fumes. Use Caution When Handling the Monitor The monitor on the operator workstation is a cathoderay tube (CRT). Breaking a CRT could cause it to implode and scatter glass fragments at a high velocity. To prevent CRT implosion, avoid rough handling or jarring of the equipment.
xvi Safety Precautions
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The S91 GERBERcutter is a computercontrolled cutting system that cuts spreads with a compressed ply height up to 7.6 cm (3.0 in.). It automates the entire cutting process, replacing handheld cutters, templates, and patterns. Instead of patterns, the GERBERcutter uses computer data files called cut files to guide its knife. These cut files are made on Gerber marker making systems such as AccuMark or MicroMark. Computeraided accuracy means accurate notches and pieces so sewing operators waste little time matching parts.
Available Models
The S91 is available in static, traveling conveyorized (TCW), and zoned valve conveyor (ZVC) models. Although these models share the same cutter control software, each is meant for specific applications, such as high ply, denim, or foam. These models also have some mechanical differences. Traveling Conveyorized (TCW) TCW systems have a moveable work surface (conveyor) and the entire cutter moves laterally across the factory floor on metal rails to service several spreading tables. The conveyor lets this system cut spreads much longer than the cutting table. TCW systems have a material clamp and a builtin vacuum generator.
Conveyor Material Clamp
Platform and Conveyor Controls
Chapter 1 S91 GERBERcutters Page 1
Static The Static system has a stationary work surface and is fixed in place on the factory floor. The base system has a single cutting table with a motorized lay puller (not shown) and external vacuum generator (not shown). Mechanically controlled vacuum zoning applies vacuum only to the area of the table surface where the spread is being cut. This feature improves cut quality and lowers power usage.
Stationary Work Surface
Zoned Valve Conveyor (ZVC) The ZVC system has a moveable work surface (conveyor) which is fixed in place on the factory floor. The conveyor lets this system cut spreads much longer than the cutting table itself. The ZVC has an external vacuum generator (not shown). Software controlled vacuum zoning applies vacuum only to the area of the table surface where the spread is being cut. This feature improves cut quality and lowers power usage.
Conveyor
Page 2 Chapter 1 S91 GERBERcutters
Note:
Unless otherwise noted, information in this chapter applies to all S91 models.
Major Subsystems
The S91 GERBERcutter has two major subsystems that work together to cut material. These subsystems are the C200 controller and the cutting table. C200 Controller The C200 controller is the command center of the GERBERcutter. Using C200MT software, the controller tells the cutting table how to cut material. The C200 has two components that work together: the Front End Processor (FEP) or PC and the motion control computer (MCC). Located in the operator workstation, the PC lets you communicate with the GERBERcutter. It sends your instructions and cut file data to the MCC. The MCC then uses these instructions to run the cutting table. Cutting Table The cutting table cuts material according to instructions from the C200 controller. All S91 models have these major parts: Cutter head and beam assembly. Beam control panel. Work surface. Vacuum generator. Mast (exhaust stack).
Other major parts depending on the model include: Conveyor. Lay puller. Limit switches. Platform controls.
Cutter Head and Beam Assembly The cutter head and beam assembly cuts material by moving a reciprocating knife across the work surface. The assembly moves in response to commands from the C200 controller. The cutter head holds the knife which both reciprocates and turns to cut corners, curves, and notches. The cutter head moves across the width of the cutting table on a beam. The beam also travels the length of the cutting table. By combining these movements, the GERBERcutter accurately cuts complex patterns. A laser origin light on the cutter head lets you position the knife to start cutting at the right place. To do this, the origin light shines a point onto the material. The beam control panel is a terminal that lets you control the GERBERcutter from the cutting table. For details on the types of beam control panels for S91 cutters, see the Beam Control Panel section later in this chapter.
Cutter Head Beam Control Panel Beam Assembly
Work Surface Laser Light Operator Workstation
Work Surface The work surface holds material for cutting. It is made of GERBER BRISTLE SQUARES that fit into plastic grids on Static systems or into aluminum slats on conveyorized (TCW and ZVC) systems. BRISTLE SQUARES are squares of molded bristle that plug into the plastic grids or slats. Each bristle square has small holes in its base. When you apply vacuum to the cutting table, air passes through these holes to hold down the material.
BRISTLE SQUARES with Grids
BRISTLE SQUARES with Slats
Vacuum Assembly To supply vacuum, the GERBERcutter uses either an external or builtin vacuum generator. The vacuum generated is used to hold the material firmly on the work surface during cutting. An external vacuum generator is connected to the cutting table by a long duct; the builtin vacuum generator on a TCW is located under the takeon end.
BRISTLE SQUARES
Vacuum Valve
Duct
The figure above shows air flow in a static or ZVC with an external vacuum generator. The vacuum generator draws air through the BRISTLE SQUARES. From there, the air travels through vacuum vents into a plenum in the cutting table, and through a duct to the external air filter and vacuum generator. The air finally exits through a remote exhaust stack, possibly located outside of the building.
BRISTLE SQUARES and Slats
Stack
Air Filter
Vacuum Generator
The figure above shows air flow in TCW systems with a builtin vacuum generator. In this case, air flows through the BRISTLE SQUARES and into the slats. From there it flows through the frame of the cutting table to the air filter and vacuum generator. The air finally exits through an exhaust stack (mast) located on the cutter.
Limit Switches Limit switches set limits for how far the cutter head and beam can move on the cutting table in the +X, -X, +Y, and -Y directions. The limit switches also tell the C200 controller when the cutter head reaches the X0,Y0 coordinate when you initialize the system. Each limit switch is activated by a specifically placed magnet or small metal plate. Example: A limit switch located on the operator side of the work surface limits cutter head movement by sensing when it has reached the home position. Further cutter head movement in this direction would not be allowed by the C200 controller.
Operator Controls Operator controls let you give commands to your GERBERcutter and respond to system messages. These controls are the: Emergency stop (EStops) switches and plungers. Circuit breakers. Table motion controls. Beam control panel. Operator workstation.
Emergency Stop Emergency Stop (EStop) is a safety feature. You must know how to use EStops before operating the GERBERcutter. An EStop halts all table motion in case of danger to people, the GERBERcutter, or the material being cut. Pressing an EStop switch or plunger immediately shuts off all power to the conveyor, vacuum generator, cutter head, and beam. All motion stops. Only the operator workstation stays on. You must perform a recovery procedure before you can use the GERBERcutter again. The figure below shows typical EStop locations.
EStop Switches
EStop Plungers
EStop Switches
EStop Switches EStop switches are large red buttons. An EStop switch is located on the operator workstation and the beam control panel. Additional button locations depend on the model.
To stop the system:
1. Press one of the red EStop switches. All table motion stops. 2. For error recovery procedures, see chapter 3 or refer to the C200MT Software Users Guide.
CAUTION:
Do not move the spread or jog the conveyor after an EStop. If you do, it will be very difficult for the cutter to start cutting in the right place.
EStop Plungers EStop plungers (sometimes called paddles) are large yellow buttons strategically located on the beam. They depress automatically whenever interference is encountered, such as someone leaning against the table when the beam is moving in that direction.
EStop Plungers
Circuit Breakers The GERBERcutter has two main circuit breakers located on the electrical panel. The electrical panel may be located on the side of the cutting table or on a separate table along side the cutting table. Both circuit breakers must be turned on for the system to run properly.
High Voltage Symbol Circuit Breaker 1
Circuit Breaker 2 (behind door) Hazard Symbol
Circuit breaker 1 provides power to the C200 controller, servo motors, and conveyor. It is in the upper left corner. You use this circuit breaker to turn on the GERBERcutter. Circuit breaker 2 provides power for the vacuum generator. It is located in the vacuum electrical enclosure. This circuit breaker is always left on.
WARNING!
Do not turn circuit breaker 2 on or off. High voltages exist within the vacuum electrical enclosure and inside the C200 controller. Never perform any work inside the vacuum electrical enclosure. There are no operatorserviceable parts inside.
Platform and Conveyor Controls Depending on the model of your S91 cutter, platform controls (for TCW) and conveyor controls (for TCW and ZVC) are provided on the operator side of the cutter at the takeon end of the table.
Platform Controls EStop Conveyor Controls
Power Button
Vacuum Readout
TCW systems have table motion control switches similar to those shown above to move the conveyor and the cutter. Table motion controls on your cutter can include: Vacuum Readout Use to monitor vacuum pressure; your cutter may have a digital readout instead of the pneumatic readout (shown). Platform Controls Use to control movement of the cutter along rails positioned between two or more spreading tables. Forward Moves the table forward laterally to align it with a spreading table or takeoff table. Reverse Reverses table movement laterally for alignment purposes. Brake Locks the table in place after positioning; ON sets the brakes and OFF releases the brakes.
Power Use to turn on power to the platform drive motors, as well as the vacuum generator and conveyor. On RSO TCW systems, this one control is located as shown; however, platform and conveyor controls are located on a panel near the stack. See page 17. Some units have power buttons (shown) while others have key switches. To turn power on with a key switch, insert the key and turn it to the left; to turn off power, turn the key to the right and remove it.
EStop See earlier section in this chapter. Conveyor Controls Use to move spreads onto the conveyor and along the cutting table. Mode Switches between Manual, Auto, and Reverse modes. In Manual mode the conveyor moves forward toward the takeoff end when you jog a spread. In Auto mode, the conveyor moves in response to commands from the C200MT program. In Reverse mode, the conveyor moves backward toward the takeon end when you jog. Jog Control Moves the conveyor backward or forward depending on how the Mode switch is set. Do not use this switch while the cutter is processing a cut file. Blower Controls whether or not air is blown up through the BRISTLE SQUARES to assist in moving a spread. If Manual is selected, the vacuum generator must be turned ON and OFF manually to blow air when you jog. If Auto is selected, the vacuum generator blows air automatically when you jog. Vacuum Controls the level of table vacuum by opening and closing the dump valve on the table. Select Dump to open the dump valve, dropping table vacuum immediately. Select Auto to allow the C200MT program to control vacuum level by automatically opening and closing the dump valve.
Beam Control Panel The beam control panel (BCP) lets you control the cutter head, beam, and certain table functions from the cutting table. Two examples of beam control panels are shown below.
Typical Panel
Flat Panel on Static Cutter
Note:
Certain controls on the beam control panel correspond to certain icon keys on the operator workstation. Refer to the C200MT Software User's Guide for further details.
The table on the following page explains how to use the switches and other components on the beam control panel.
Component
Description EStop Immediately stops all table motion. Knife Turns the knife motor on or off. Manual Mode Light Checks for head and beam movement; lights up when the head and beam are both stopped. Feedrate Dial Sets the feed rate at which the cutter head and beam move across the table. The range is from 1 (minimum) to 15 (maximum); 0 is no movement. Cutting speed is the same as feed rate. Joystick Moves (slews) the cutter head and beam in the direction of the arrows. (-X, +X, -Y, or +Y); the Slew Enable switch must first be depressed. Slew Enable Allows movement of the cutter head and beam; depress and hold before using joystick. Error Warning Light Checks joystick functions; lights up when the cutter is in Manual Bite or Trim Cut mode or when a controller error occurs. Stop Stops the current operation of the cutter. Vacuum Turns cutting table vacuum ON or OFF. KI Null Resets Knife Intelligence. Fabric Alignment Sets fabric alignment when pressed twice. Manual Bite Switches between Manual Bite mode and Auto mode. Initialize Moves the cutter head to the home X0,Y0 position on the table. Trim Cut Manually trims the edges of a spread. Origin Sets the current position of the origin light as the origin of your marker. Marker origin is the X,Y coordinate where the marker starts. Note: The C200MT program takes into consideration the mechanical offset between the knife and the origin light. Start Starts the GERBERcutter. Sharpen Knife Manually sharpens the knife blade one cycle.
Operator Workstation You use the operator workstation and the beam control panel to run the GERBERcutter. The operator workstation on your cutter looks similar to the figure shown below. The operator workstation may also be called front end processor (FEP) or PC.
Monitor
Speakers
EStop Icon Keys Servo Power Enable
Keyboard
CDROM Drive 3.5 in. Disk Drive Pointing Device Hard Drive
Monitor Receives computer video signals from the PC and displays information on the screen. Speakers For use with Computer Based Training. Keyboard Device with keys, like those on a typewriter, that lets you enter data and communicate with the C200MT program. Icon (function) keys Each key performs a C200MT command to operate the cutter. The icon (picture) and color of the key tells you which key performs each function. Refer to the C200MT Software User's Guide. Pointing device Moves the cursor around the screen to select cut files, setups, or pieces and enter menu commands and information in dialog boxes. Your pointing device may differ from the one shown above; refer to the C200MT Software Users Guide.
Servo power enable Pushing this button turns on power to the servo motors. These are motors that move the cutter head and beam as the GERBERcutter cuts material. Emergency stop See section earlier in this chapter. 3.5 inch disk drive C200MT software and cut files are stored on disks before being copied into the hard drive of the operator workstation PC. Disks come in two sizes: 3.5 and 5.25 inches. CDROM drive Use for accessing Computer Based Training and Service Parts; see chapter 7 and check availability with your local GGT Sales and Service office. Hard disk drive The hard disk drive holds the C200MT software that runs the GERBERcutter. A hard disk drive uses rigid metal disks so it can store much more data than a 3.5 inch disk. You need to manage your hard disk so it does not become too full and disorganized. Refer to Windows NT documentation and the C200MT Software Users Guide for information on managing files on the hard disk. Options There are many options for tailoring the S91 to the material you cut and your way of doing business. Here is a partial list of hardware and software that may be useful as you become more familiar with your system. For more information, call your local GGT Sales and Service office. Spare Cutter Head (Without Covers) This cutter head replaces the cutter head running on the system to ensure minimum downtime during maintenance and repairs. Spare Sharpener Assembly This sharpener assembly replaces the sharpener assembly running on the system to ensure minimum downtime during maintenance.
Right Side Option The right side option lets you run the GERBERcutter from the right side of the cutting table. This lets you spread material with its straight edge on the right side, which is more practical for some applications. Operator controls are moved to the right side where appropriate. Shown below is a TCW system with the RSO option.
Conveyor and Platform Controls
Electric Drills
Beam Control Panel
Electric drills are available as single, dual, and heavy duty units. GGT also provides drill bits in a wide variety of sizes and types. CTOT A Conveyorized Take Off Table is available for use with the TCW and ZVC models. The CTOT AUTO Enable control is located on the operators side of the CTOT.
Cutter Info Database (CIDB) CIDB is an optional time reporting software that helps you judge how well you are using your GERBERcutter. CIDB records how long various cutting activities take and provides reports that can help you decide how you can do things better. For example, CIDB may show that a certain cut file keeps the knife out of the material too long, increasing cutting time. These are some of the data CIDB records: Marker being cut. Cutting speed. Cutting time (blade in the material). Dry haul time (blade out of the material). Cutter stop time while cutting a cut file. Time used to prepare and align next spread.
POWER Processor The POWER Processor lets you change cut files so that the GERBERcutter works more efficiently. Input to the POWER Processor is a cut file produced on a marking and grading system such as GGTs AccuMark or MicroMark. Output is a modified cut file. Altering a cut file can improve cut quality, cut speed, material use, and cut file efficiency. The POWER Processor lets you: Change piece cutting sequence. Change the start point of a piece. Add or remove knife lift and plunge points. Add or remove Optional Stop points for plaid/stripe matching. Some features of the POWER Processor are now included in the PreProcessor utility of the C200MT program. See chapter 4.
Note:
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Note:
Information in this chapter applies to all S91 models unless otherwise noted.
Direction and Location

GGT uses specific terms to describe direction and location on the cutting table. Learning these words will make it easier for you to find your way around the GERBERcutter. Ends and Sides Each side of the cutting table is named so you can identify it easily. The takeon end is where material comes onto the work surface for cutting. The takeoff end is where material leaves the work surface after cutting. The right and left sides are as they would appear to someone standing at the takeon end.
Right Side (Far Side)
Takeoff End (ZVC / TCW) Left End (Static)
Takeon End (Right End on Static)
Left Side
Beam Control Panel
Chapter 2 Basic Concepts Page 19
X, Y, and Caxes The GERBERcutter uses three imaginary lines or axes to tell direction and location on the cutting table. They are the X, Y, and Caxes, as shown below.
If you stand at the operator workstation, the Yaxis runs across the table, the Xaxis goes from left to right, and the Caxis is in the cutter head. The beam moves along the Xaxis, the cutter head travels the Yaxis, and the knife turns around the Caxis in the cutter head. Movement is always in a plus (+) or minus (-) direction on the X and Yaxes. If you stand at the operator workstation: +X is to your right. +Y is away from you. -X is to your left. -Y is toward you.
Location is also given in terms of the X and Yaxes, as shown below.
Page 20 Chapter 2 Basic Concepts
If you stand at the operator workstation, the point X0, Y0 is at the lower left corner of the work surface, as shown below.
X0, Y0
All locations on the work surface are relative to this position. Unlike direction, location is always stated in positive numbers. To find the point (X=24 in., Y=36 in.), start at X0, Y0. Measure 24 in. to the right along the Xaxis. From there, measure 36 in. away from you on the Yaxis . You are now at the point X24, Y36.
Origin
Just as the table has a X0, Y0 position marking its lower left corner, so does each marker. The X0, Y0 position of the marker is called the origin. All data points (locations) of the marker are relative to the origin. Before the GERBERcutter can cut a marker, you must set the location of the origin. The cutter then cuts each piece relative to this point. The origin is set from the beam control panel or at the operator workstation (see chapter 3). The origin light is a red laser light located in the cutter head that shines on the cutting table (see the Safety chapter at the beginning of this manual).
WARNING!
The origin light uses a Class IIIa laser. Do not look directly into the laser beam without protective glasses. Do not place any reflective (shiny) material on the cutting table. Remove watches, rings, and other jewelry. Reflected laser light may cause eye injury.
The origin must be close enough to the lower left corner of the table so that the marker can fit on the table. For example, the origin shown below is at X25, Y50.
With that origin, the marker extends off the table in the Y direction. You can correct this situation by moving the origin to X25, Y25.
If the cutter cannot cut the marker because it will go off the table, you will receive an off table message, such as one of the following:
Off table in +Y Off table in -X
Using the Check Origin feature, the system automatically verifies that the marker will fit on the cutting table with the current origin. It does this before cutting the marker. If the origin will not work for your marker, the system displays an error message like this:
Bad Origin: X too high (x.xxx) acceptable range: x.xxx - x.xxx
where x.xxx is a table location in the X direction. You get a similar message if the origin needs to be corrected in the Y direction.
Bite Feeding
TCW and ZVC systems use a conveyor for bite feeding. Bite feeding is a feature that matches cutter head movement with conveyor movement, permitting automatic cutting of a long spread. The GERBERcutter does this by cutting the spread in sections. The marking system sets the length of each section in inches or centimeters as one bite. After the cutter pulls the bite onto the cutting table and cuts it, the conveyor automatically advances, positioning the next bite on the cutting surface. An example of how the conveyor and bite feeding work is shown on the next page. Diagram 1 shows a 48.8 m (160 ft.) spread of material that the marker maker has divided into 20 bites, each 2.4 m (8 ft.). To begin automatic cutting, the conveyor pulls the leading edge of the spread onto the cutting surface with the aid of underlay paper. The conveyor moves until it pulls the first bite onto the cutting table as shown in Diagram 2. The GERBERcutter cuts the first bite, including pieces that extend into the second bite As shown in Diagram 3. The knife cuts a slit in the selvage of the material to mark the origin of the second bite. The slit (or edge clip) made by the marking system is a reference point in case you stop cutting during the second bite.
Next, the conveyor automatically moves the first bite down the cutting table and brings the second bite in position to be cut as shown in Diagram 4. While the bundle handlers are removing the pieces from the first bite, the GERBERcutter begins cutting the second bite. After the system completes the second bite, the conveyor moves the third bite onto the cutting surface. It brings the second bite down to the bundle handlers, and moves the first bite scrap from the cutting surface to the takeoff table, where you can collect or discard it as shown in Diagram 5. The GERBERcutter keeps feeding bite after bite until it cuts the whole spread.
Software and Files

Software Software is the set of computer programs that the C200 controller uses to run the GERBERcutter and communicate with you. These programs include: C200MT Cutter control software that reads cut files and setups to tell the cutting table how to cut material; this program starts up automatically when you power on the GERBERcutter. Windows NT Operating system for the PC at the operator workstation.
For more information about C200MT software and Windows NT, refer to the C200MT Software User's Guide. Cut File A cut file is a computer data file that tells the GERBERcutter how to cut a set of patterns (a marker) out of a spread of material. The cut file is generated by a GGT marker making system such as the AccuMark or MicroMark. Setup A setup is a computer data file that sets up the system for the materials being cut. For example, you may have one setup for cutting denim and another for flannel. The C200MT software comes with several default setup files. See chapter 4.
Note:
Setups were previously called Configuration or Config files.
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Sections in this chapter explain: Spreading material. Basic cutting on your GERBERcutter. Beyond the basics. Recovery after an EStop or system power down.
For additional information on how to use C200MT program features, refer to the C200MT Software Users Guide.
Chapter 3 Cutting Markers Page 27
Spreading Material
CAUTION:
Different materials require specific spreading methods for the best cutting results. Also, Static systems have different spreading requirements than TCW and ZVC systems which have conveyorized tables. The following procedures are general guidelines only.
To spread material on the spreading table
1. Place an underlay of perforated or airporous paper (25 to 60 lbs.) on the spreading table. Be sure the paper is straight on the table and extends at least 0.3 m (1 ft.) beyond the leading edge of the spread. For Static systems this should extend approximately 1 m (or 3 ft.) beyond. The underlay lets you move the spread without pulling or disturbing the material. When vacuum is applied, the underlay keeps the material clean and in place. It also provides extra support for stretchy and lightweight material. 2. Using the method appropriate for your site, spread the material on top of the perforated paper. Normally the straight edge is on the operators side of the cutting table.
CAUTION:
Do not exceed your GERBERcutters maximum compressed material ply height 7.6 cm (3.0 in.). Exceeding the maximum material ply height will lower cut quality, shorten knife life, and may damage your GERBERcutter.
3. If you use fullsize plots to identify individual pieces after they are cut, put the correct one on top of the spread.
Page 28 Chapter 3 Cutting Markers
Basic Cutting
The following sections explain the basic steps, shown in the diagram below, required to a cut a marker on a GERBERcutter.
At Cutter At Operator Workstation
1. Turn on cutter 2. Enable servo power
3. Initialize cutter
4. Position first bite 5. Select setup
6. Open marker
7. Turn on vacuum 8. Turn on laser
9. Position laser light
10.Set marker origin
11. Select cutting speed
12. Turn on knife motor 13. Start processing marker
14. Recovery (if needed)
WARNING!
Read the safety precautions at the beginning of this manual before performing any operation at the cutter.
Turning on the Cutter Turning on, or powering up, the cutter automatically opens Windows NT and runs the C200MT program at the operator workstation.
To turn on the cutter
1. Make sure that no limit switch is parked on its magnet (see chapter 1). If necessary, manually move the cutter head or beam toward the center of the work surface. 2. At the beam control panel, set: a) Knife button b) Feed rate to OFF. to a low speed, such as 2 or 3.
3. For TCW systems, turn on the table power circuit breaker (approximate location shown below). For Static and ZVC systems, turn on circuit breakers at the panels for the external vacuum and for table power or the lay puller.
C200 Controller
Table Power (not shown)
4. Turn on circuit breaker 1 for the C200 controller. The control panel is located on the right side of TCW systems; for other S91 cutters, the C200 control panel may be located on a nearby table.
Circuit Breaker 1
Enabling Servo Power Pressing the Servo Power Enable button turns on power to the servo motors. These motors control movement of the cutter head and beam during cut processing.
To enable servo power
1. Make sure that cutter power is turned on and the C200MT program is running. 2. At the operator workstation, press the Servo Power Enable button. The servo motors are turned on and gauges display across the top of the C200MT Main Cutter Control screen. 3. If nothing happens when you press the Servo Power Enable button, do all of the following: Make sure that no limit switch is parked on a magnet. If necessary, manually move the cutter head or beam toward the center of the work surface. Make sure all EStop switches are up; if not, twist clockwise. Make sure no EStop plunger is activated.
Initializing the Cutter Initializing the cutter identifies the zero position for the table in X and Y. This is also called the home position and is written as (0,0). Limit switches (see chapter 1) tell the C200MT program when the cutter head reaches the (0,0) position.
Note:
You must initialize the cutter before processing markers. Otherwise, an error message displays.
To initialize the cutter
1. Make sure that the cutter power is turned on and the servo power is enabled. 2. Do one of the following: Press the Initialize button on the beam control panel.
Press the Initialize key on the keyboard. The cutter head and beam moves to the (0,0) position on the table. A new origin is reported in the System Messages box.
Note:
If the cutter is set up for the Right Side Option, the cutter head and beam moves to the right side of the table.
Positioning the First Bite After the cutter is initialized, use the jog switch at the takeon end of the cutter to advance the spread (material) into cutting position. On TCW and ZVC Systems These systems use a conveyor to jog, or move, the spread into position on the cutting table. TCW systems also use the clamp bar to help the conveyor move the spread.
To position the first bite
1. Manually pull about 1 m (3 ft.) of the spread onto the cutting table. 2. Use the jog control switch to advance the conveyor until the spread is about 25 cm (10 in.) from the takeoff end of the cutting table.
CAUTION:
Do not advance the conveyor too far. You can not reverse the conveyor without disturbing the spread.
3. Manually pull the plastic film overlay (polyethylene) from the film dispenser to cover the entire bristle surface. This allows proper vacuum compression.
CAUTION:
If not positioned carefully, the plastic film can get caught in the racks along which the beam travels. To avoid damage to material and your GERBERcutter, keep the plastic film away from the racks.
On Static Systems Static systems use a motorized lay puller to move the spread into position on the cutting table.
To position the first bite
1. The tow bar assembly of the motorized lay puller must be located at the spreading table. If not, return it to this position. 2. Wrap the 1 m (3 ft.) extended end of underlay paper up over the spread. See the Spreading Material section in this chapter.
3. Manually pull the spread and underlay paper onto the lower portion of the tow bar assembly. Initiate clamping to lower the upper portion of the tow bar assembly. 4. At the cutting table, turn on the motorized lay puller. The tow bar is pulled along the cutting table. 5. When the spread covers the length of the cutting table, turn off the motorized lay puller. Raise the upper portion of the tow bar assembly and position the end of the spread flat on the table. The tow bar waits at this end of the table until all pieces are cut and removed from the table. 8. Manually pull the plastic film overlay (polyethylene) from the film dispenser to cover the entire bristle surface. This allows proper vacuum compression.
CAUTION:
If not positioned carefully, the plastic film can get caught in the racks along which the beam travels. To avoid damage to material and your GERBERcutter, keep the plastic film away from the racks.
Selecting a Setup The C200MT program includes default, or preset setups, that configure the system for most cutting applications. A setup is a file containing parameters which enable or disable various features, options, and modes. Preset setups are based on characteristics of the spread. For information on customizing setups, refer to the C200MT Software Users Guide.
To select a setup
1. Do one of the following: Press the Settings key on the keyboard.
From the Setup menu, select Settings. 2. If some other page is selected, click the Setup List tab. 3. Use the pointing device to select the Name of the setup you want.
Note:
To enter or edit a description for the setup you just selected, click in the field at the bottom of the page and type a new description.
4. To select this setup as the current setup, click the Apply or the OK button. 5. When prompted to Activate the selected Setup, check your changes and then click the Yes button. 6. When satisfied with the changes, press Enter or click the OK button. Your system is now configured.
Opening a Marker Use the Marker Open feature to select a marker, or cut file, and open it for processing. The default directory for markers is C:\USER. To change the default directory, refer to the C200MT Software Users Guide.
To open a marker
1. Do one of the following: Press the Open Marker key on the keyboard.
From the Marker menu, select Open. 2. If you know the name of the marker you want to open, type the name in the Marker Select dialog box. Press Enter or click the OK button. Go to step 6. OR To view a list of available markers on the hard disk, network, or disk drive(s), press Enter or click the OK button. The Marker Open screen displays.
Note:
For a Right Side Option cutter, you will be prompted to enter a new marker width. Press Enter to accept the marker width or type a new marker width and then press Enter.
3. To change drives and directories, use the pointing device, Tab key, or Arrow keys to select a drive and then a directory.
Note:
To view files on a different 3.5 inch or 5.25 inch disk, insert the new disk and click the Rescan Drives button.
4. Select the marker you want to process. 5. Press Enter or click the OK button to return to the C200MT Main Cutter Control screen. 6. The first bite of the selected marker is processed and displays in the Marker Plot screen. Verify that this is the marker you want to cut.
Turning on the Vacuum Use the Vacuum feature to turn on the table vacuum in order to process markers. When finished cutting, you can repeat the following procedure to turn off the table vacuum. For information about setting vacuum features, refer to the C200MT Software Users Guide.
To turn the vacuum on in order to cut
1. Make sure that the first bite is positioned on the table and the correct marker is open. 2. Do one of the following: Press the Vacuum On/Off button on the beam control panel.
Press the Vacuum key on the keyboard. Turning on the Laser Light The laser origin light is turned on by pressing a button located on the cutter head. This light is used to visually locate the marker origin on the cutting table.
WARNING!
The origin light uses a Class IIIa laser product. To avoid injury to your eyes, do not look at the laser at any time. Also, do not place any reflective material, such as mirrors, polished steel, or jewelry on the cutting table.
Setting the Marker Origin Use the Origin feature to establish the origin, or X,Y position, for a marker.
To set the marker origin
1. At the beam control panel, make sure the Feedrate dial or 2. 2. Press and hold the Slew Enable button.
is set to 1
3. Use the joystick and then press the Arrow buttons to move the cutter head until the laser origin light falls on the lower left corner of the spread. 4. Release the Slew Enable button. 5. Do one of the following: Press the Origin button on the beam control panel.
Press the Origin key on the keyboard. The origin is reported in the System Messages box, where x.xxx and y.yyy are the absolute table coordinates (origin) for the lower left corner of the marker.
Note:
If you use Fabric Alignment to adjust for a spread that is not straight on the cutting table, do so now. See the Beyond Basics section later in this chapter.
Selecting Cutting Speed

To select cutting speed
1. At the beam control panel, use the Feedrate dial to select the appropriate cutting speed for processing the open marker. This speed depends on the material being cut; 5 is a good starting speed. 2. To manually adjust cutting speed, use the Feedrate dial, as needed, throughout the marker. OR Cutting speed can be automatically adjusted, for example when cutting corners, by parameter settings in the Setup file. Refer the C200MT Software Users Guide. Turning on the Knife Motor
WARNING! The knife blade is very sharp. Be extremely careful when working near the knife blade. See the Safety Precautions chapter at the front of this manual.
To turn on the knife motor
At the beam control panel, use the Knife switch knife motor. The knife reciprocates (moves up and down).
to turn on the
Processing a Marker Use the Start feature to begin processing, or cutting, a marker.
To start processing a marker:
1. Make sure you have completed all the procedures previously explained in this chapter.
WARNING!
Check that it is safe to begin cutting! Make sure nobody is near the cutter head, beam, and conveyor.
2. Do one of the following: Press the Start button on the beam control panel.
Press the Start key on the keyboard. The piece being cut is outlined in the Marker Plot screen and the current piece and bite number display in the System Status window. 3. When prompted that processing is complete, press Enter or click the OK button.
Exiting the Program This section gives the steps necessary to close the C200MT program and shut down the cutter.
CAUTION:
To avoid losing data, always quit the C200MT program before shutting down Windows NT. Also, shutdown Windows NT before turning off the main circuit breaker for the cutter.
To quit the C200MT program
1. Make sure that the cutter is idle (not processing data). 2. From the Quit menu, select Confirm.
To shut down the cutter
1. From Windows NT, do one of the following: From the File menu, select Shutdown. Or, press ALT + F4. Click the Start button and then click Shutdown. 2. In the Shutdown dialog box, click the radio button next to Shutdown. Then press Enter or click the OK button. 3. When prompted that it is safe to turn off your computer, turn off the circuit breaker for the C200 controller. 4. For TCW systems, turn off Table power. For Static and ZVC systems, turn off power at the panels for the external vacuum and for table power or the lay puller.
Beyond the Basics

Besides allowing you to cut a marker using the basic steps, the C200MT program provides commands and parameters for specific cutting applications. This section explains how to use: Fabric Alignment. Pause Between Bites. Data Scale Factor. Trim Cut. Move to Origin.
For more information on parameters, refer to the C200MT Software Users Guide. Using Fabric Alignment Fabric Alignment can be used to cut a spread that is skewed relative to the cutting table. This is done by selecting two points along the length of the spread to define an adjustment angle. Use with Pause Between Bites (see next section).
To cut a skewed spread
1. Make sure that the Check Origin parameter in the Options and Modes category is turned off. 2. Set the origin for the marker. 3. To define a new angle:
WARNING!
Check that it is safe to move the cutter head and beam! Make sure nobody is near the cutter head, beam, and conveyor.
a) At the beam control panel, press and hold the Slew Enable button. b) Use the joystick and Arrow keys to slew the laser origin light to a point along the spread that is the same distance in Y from the edge of the marker as the origin. c) Release the Slew Enable button. d) Press the F2 button twice.
4. To use the previous angle: a) From the Cutter menu, select Fabric Alignment. b) Click the Recall button onscreen. 5. Between each bite, repeat step 3 or 4 as needed. Using Pause Between Bites It is possible to stop the cutter between bites in order to perform a procedure, such as setting origin or fabric alignment.
To use pause between bites
1. Edit the setup using Parameter Manager and the Bite Parameters category. Refer to the C200MT Software Users Guide. The cutter will pause automatically between each bite. 2. When cutting stops, complete any necessary procedure. 3. Process the next bite. Using Check Origin Check Origin can be used to check whether or not the entire marker will fit on the usable table surface based on the current origin. For example, if the X value of the origin is too great, pieces at the takeon end of the current bite might not cut properly.
To check the origin
1. Edit the setup using Parameter Manager and the Options and Modes category. Refer to the C200MT Software Users Guide. 2. Open and set the origin for a marker as usual. 3. If pressing the Start button results in a system prompt of Bad Origin: a) Reposition the cutter head within the acceptable range, as prompted. b) Set the Origin and press the Start button again.
Using X Data Scale Factor, Y Data Scale Factor On occasion you may need to adjust scaling for cut file data so that a marker will fit on the available material. Scaling can be adjusted in either X, Y, or both X and Y directions.
To use a data scale factor
1. Calculate the X data scale factor by dividing the usable material length by the marker length. 2. Calculate the Y data scale factor by dividing the usable material width by the marker width. 3. Edit the setup using Parameter Manager and the Data Format/Scaling and RSO category. 4. Open and process the marker.
CAUTION:
To avoid cutting the next marker incorrectly, return each data scale factor to 100% after cutting the current marker.
Using Move To Origin Use the Move to Origin feature to move the cutter head to the last established origin. You can use this command whenever you want to verify the origin; for example, use after Fabric Alignment.
To move to the last established origin
1. Do one of the following: Press the Move to Origin key on the keyboard.
From the Cutter menu, select Move to Origin. The cutter head and beam moves to the last established origin which is reported in the System Messages box.
Using Trim Cut Use the Trim Cut feature to trim away excess material and plastic after cutting a marker.
To trim
1. Do one of the following: Press the Trim Cut button on the beam control panel.
From the Cutter menu, select Trim Cut. 2. At the beam control panel, use the slew keys to make required cut(s). 3. To exit Trim Cut mode, do one of the following: At the beam control panel, press the Stop At the operator workstation, press Esc. button.
Recovery from Interrupted Cutting

Recovery procedures allow the cutter to resume cutting after a power loss, EStop, or a system power down interrupts cut processing. An EStop occurs whenever cutter motion is stopped by pressing one of the emergency stop (EStop) switches or plungers located on the cutter.
Note:
The reason for the power down displays as an onscreen error message.
Recovery procedures include: Restore State Return to the last piece and bite being cut. Restore Origin Restore origin for the current marker. Bite Search Find and cut a specific bite. Piece Search Find and cut a specific piece. Piece Recut Recut a specific piece.
Before Using Recovery Commands Before using any of the recovery commands you need to perform the following procedures.
To correct the condition before recovery
1. If the operator workstation lost power, turn on the main power supply and start up the C200MT program. Then enable servo power and initialize the cutter. OR If an EStop occurred, press Enter to clear the message from the screen. Enable servo power. OR If accidental system power down occurred, press Enter to clear any error message from the screen. Restart Windows NT, if necessary, and restart the C200MT program. Then enable servo power and initialize the cutter.
Using Restore State Use the Restore State feature to return to the last piece and bite that was being cut before a power loss, EStop, or system power down. This feature automatically restores all of the following: Reopens the cut file. Restores the setup. Restores Fabric Alignment. Restores the origin. Restores the bite (TCW or ZVC systems). Searches for the piece being cut before the cutter stopped. Restores a Job Queue (see chapter 4).
To restore state of last marker
1. Make sure that the condition which stopped cutting is corrected. 2. Do one of the following: Press the Restore State key on the keyboard.
From the Recover menu, select Restore State. 3. If the marker and piece information displayed in the Restore State dialog box is correct, press Enter or click the OK button.
Note:
If this information is not correct, you can use the procedure for restoring state manually. See the next section.
The marker is opened and the System Message box prompts that the State is restored. 4. Verify that the correct piece and bite number display in the System Status window. If correct, start processing.
Restoring State Manually Instead of using the Restore State feature, you can manually restore state using the following steps.
To restore state manually
1. To set the origin, do one of the following: Position the origin light at the top of the bite clip for the last bite cut. Set a new origin. If restoring the first bite (TCW or ZVC), use the origin or set origin as normal. 2. Choose the correct setup to configure your cutter. 3. Open the marker. 4. Use Piece Search explained in the next section.
Using Piece Search Use the Piece Search feature to find and cut a specific piece in a marker. This is useful after an EStop or system power down, especially if the Restore State command does not find the correct piece to cut.
To find and cut a specific piece
1. If cutting was interrupted, make sure that the condition is corrected and the marker you want to cut is open. 2. Do one of the following: Press the Piece Search key on the keyboard.
From the Recover menu, select Piece Search. 3. In the Piece Search dialog box, type to enter the Piece to Search to. Then press Enter or click the OK button. The Marker Plot screen shows the piece in the marker. The System Messages box reports that the requested piece was found and gives the bite number it was found in (TCW and ZVC systems).
Note:
When the piece being searched for is split across two bites, a dialog box displays. If you want to begin cutting the part of the piece located in the first of these two bites, click the Yes button. If not, click the No button.
Using Piece Recut Use the Piece Recut feature to recut a specific piece in a marker that might not have been cut properly.
To recut a specific piece
1. Make sure the marker you want to cut is open. 2. From the Recover menu, select Piece Recut.
3. In the Piece Recut dialog box, type the piece number to recut. Then press Enter or click the OK button. The piece you want to recut displays alone in the Marker Plot screen. The System Status window reports that the requested piece was found and gives the bite number it was found in (TCW and ZVC systems). 4. Position material on the table. 5. Position the cutter head near the lower left corner of the area to be cut. 6. Set the origin. 7. Start processing. Using Restore Origin Use the Restore Origin feature to restore the origin point.
To restore the last origin
1. Make sure that the condition which stopped cutting is corrected. 2. From the Recover menu, select Restore Origin. The origin is reported in the System Messages box, where x.xxx and y.yyy are the absolute table coordinates for the restored origin point. Using Bite Search For TCW and ZVC systems, use the Bite Search feature to find and cut a specific bite in a marker.
To find and cut a specific bite
1. If cutting was interrupted, make sure that the condition is corrected and the marker you want to cut is open. 2. From the Recover menu, select Bite Search. 3. In the Bite Search dialog box, type to enter the Bite to Search to. Press Enter or click the OK button. The System Messages box reports that the requested bite is found and gives the piece number of the first piece in that bite.
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This chapter presents a brief overview of the following C200MT utilities: Parameter Manager Customizes setups by editing parameter settings. Run Time Biting Bites markers for cutting. PreProcessor Preprocesses cut file data to reduce cutting time and material waste when cutting the marker. View Marker Displays pieces and bites in a marker and plays back how the marker will cut. Queue Manager Creates and edits job queues for processing a select batch of markers. File Manager Manages marker files, performing such tasks as copying, moving, renaming, and deleting. CIDB Generates reports about markers processed on a GERBERcutter.
Chapter 4 Utilities Page 51
Parameter Manager
The Parameter Manager allows you to: Change parameters for one or all setups, temporarily, or permanently. Create a new setup. Change the current setup. Print the current setup. Search for a specific parameter. Assign access levels to parameters. Customize the Frequently Used Parameters category for your needs.
For information on using the Parameter Manager, refer to the C200MT Software Users Guide. Access Levels by Password Access to specific parameters can be restricted in order to prevent accidental changes. The C200MT program allows for four levels of access to the Parameter Manager. User. Supervisor (password required). Field Service (password required). Software (password required).
Parameters and Categories Parameters are settings that are included in the setup for your cutter. Some parameters turn a feature on or off. Other parameters define a value within an allowable range. Categories group parameters that relate to a cutter feature. See the table on the following page.
Page 52 Chapter 4 Utilities
Categories that can be accessed at the user level are listed in the table below. For Field Service level parameters and information about individual parameters, refer to the C200MT Software Users Guide.
Category Frequently Used Parameters Knife and Drill Speeds Sharpen Parameters Parameters Used To Provide quick access to frequently used parameters; this category can be customized. Control knife and drill speed for specific cutting conditions. Control how and when the knife is sharpened. Define how the cutter determines wear on the knife blade and when the knife should be replaced. Control advance and overcut distances and limits. Control cut angle and slowdown percentage for cutting operations. Control the vacuum options. Tell the cutter to ignore or respond to certain marker data codes. Control times and number of sweeps for automatic cleaning. Control how Knife Intelligence compensates for cutting forces on the knife. Set up Path Intelligence to automatically adjust feed rate for the best cut quality and throughput. Define the format of cut file data or AAMA data conversion. Define X and Yaxis scaling. Define marker size. Initialize RSO cutters. Define how the cutter handles bites. Define end park position. (TCW and ZVC systems) Turn on/off various GERBERcutter features. Turn on the mirroring options which rotate the marker before cutting. Turn on the clipping window feature and define boundaries. Control how the cutter responds to Opstop codes. Define Cutter Info Database (CIDB) reporting. Control Selvage/Web cutting for vertical line cuts through the selvage or the selvage and web. Control processing of consecutive markers. Set maximum beam velocities for dry haul and cutting. Check system setup parameters set by field service. Set preferences for handling cut files and job queues in Queue Manager. Set parameters for the Preprocess utility.
Cutting Parameters Vacuum System Ignore Codes Bristle Cleaner Knife and Path Intelligence
Data Format/Scaling and RSO
Bite Parameters Options and Modes Mirror Image and Clipping Window OPSTOP and Report Options Selvage Cut/Contiguous Cut
System Setup Parameters Queue Manager Cut File Preprocessor
Run Time Biting

For TCW and ZVC systems, the Run Time Biting utility bites the marker, designating sections of the marker for automatic cutting. Each bite fits on the cutter table and can be cut at one time. Run Time Biting can take place either while: Cutting a marker. Preprocessing a marker with Bite Generation (see PreProcessor section in this chapter).
Settings for Bite Parameters determine the length of the bites and whether they are equal (static length biting) or variable in length (variable length biting). For diagrams showing biting, see chapter 2. Also, refer to the C200MT Software Users Guide. Static Length Biting Static length biting divides the marker into bites of equal lengths. If a piece extends beyond the bite, the cutter splits the piece and only cuts the portion of the piece that fits within the bite. When the cutter has finished cutting all pieces or parts of pieces for that bite, the conveyor advances the next bite. The cutter then cuts the second portion of the piece. Variable Length Biting When Variable Length Biting is turned on, the cutter only splits those pieces too large to fit on the cutting table. This feature is useful to: Eliminate split pieces in a marker requiring pieces not be split. When matching plaids and stripes in split pieces.
Using Variable Length Biting, the cutter cuts all pieces in a given bite that completely fit on the table. The conveyor then advances to the uncut piece farthest to the left. It cuts that piece and any other whole pieces on the cutting table. The conveyor again advances to the uncut piece farthest to the left. This step is repeated until all pieces are cut. Variable length bites usually are shorter and occur more often than static length bites.
PreProcessor
Use the PreProcessor utility to process and organize cut file data in order to reduce cutting time and material waste when cutting the marker. Without preprocessing, all lines for each piece in a marker are cut before the next piece is cut. The PreProcessor utility optimizes on the normal cutting strategy by using bite generation and features from the GGT POWER Processor program: Bite Generation Generates bite data before preprocessing (see the Run Time Biting section on the previous page). Reorder Resequences the order in which pieces will be cut in a marker. Common Line Cuts common lines only once. Path Optimization Cuts pieces more efficiently.
For information on using PreProcessor, refer to the C200MT Software Users Guide. Reorder Reorder allows the system to automatically determine the sequence in which marker pieces are cut based on parameters that you can define or change. Common Line Common Line analyzes and reorganizes cut files so that all common lines are cut once. A common line is a line that is shared by two neighboring pieces in a marker or cut file. This feature can save cutting time and improve cut quality in common line regions when cutting markers with blockshaped pieces. Path Optimization Path Optimization analyzes pieces in a cut file and looks for more efficient ways to cut them. For example, four neighboring pieces, semicircular in shape, might be cut as a figure 8.
View Marker
Use the View Marker utility to access the GGT Cutview screen. Features in the Cutview screen allow you to: View a marker. Change the view scale. Overlay a grid. Display dry haul lines, bite lines, drill points, and data points. Change default colors. Playback onscreen how the cutter is going to cut the marker, piece by piece.
For information on using View Marker, refer to the C200MT Software Users Guide. Selecting Pieces To select a piece, first click the Piece Select button and then click inside the piece that you want to playback or get information about. Information about the cut data for the piece displays onscreen in the Piece Data window. Tool Code Reference Use the Tool Code Reference command in the Cutview Help menu to find a description and example of the tool codes that may display in the Piece Data window. Playing Back a Marker Cutview provides three options for playing back cut data in a marker. Animate Use to playback a marker, cutting pieces according to piece number sequence. Piece by Piece Use to switch playback modes so that cut data displays one piece at a time, beginning with a selected piece. Segment by Segment Use to switch playback modes so that cut data for a selected piece is displayed one line segment at a time.
Queue Manager
When processing a batch of markers, use the Queue Manager utility to: Create a job queue. Run a job queue. Close a job queue. Select the next job in a queue. Edit a job queue.
Queue Manager runs minimized (an icon or task bar button displays at the bottom of the screen) while the C200MT is running a queue. For information on using the Queue Manager, refer to the C200MT Software Users Guide. Job Queues A job queue contains multiple markers to be cut sequentially. Each marker and the corresponding setup file are called a job. Each job is opened, processed, and closed automatically until all jobs have been processed. Using job queues can increase throughput because queues can be created while other markers are being processed and then run automatically. More than one job queue window can be open at a time in the Queue Manager screen. Defaults for Queue Manager To simplify creating and editing a job queue, the Queue Manager uses the following default files and directories: Location of available markers C:\USER Setup to use when adding a job DEFAULT.CNF
Queue Manager defaults can be changed using the Change Defaults command in the Tools menu of the Queue Manager screen.
File Manager
Managing cut files is an important task. You can use the File Manager utility to perform the following routine data management tasks: Copy files from a disk or a network drive to the hard drive of the cutter. Move files to another directory on the hard drive. Rename files from a previous season. Delete files after backing them up to disk or to the network. Manage directories.
Note:
If you are familiar with Windows NT 3.51 or Windows 3.1 File Manager, you already know how to use features in the C200MT File Manager. For those learning how to use Windows, refer to the C200MT Software Users Guide or refer to your Windows documentation for additional information.
Directories and Files Directories and subdirectories help organize cut files, for example by style or season. Use the File Manager utility to create or delete directories. File Manager uses a window to display information about the directories and files for each drive. More than one drive window can be open at a time. At the left of the drive window is a directory tree showing all directories on that drive. Click on a directory to display all files for that directory. Using Paths to Locate Files When managing marker files, you may find it easier to type the path to locate a file rather than making selections with the pointing device. A path is all the information (drive, directory, and any subdirectory) the system requires to locate a directory or file. Items in the path are separated by the backslash (\). For example, to select files in the sub-directory SLACKS in the WINTER directory on the network H drive, type H:\WINTER\SLACKS.
Using Wild Cards to Locate Files Using a wild card can simplify managing multiple files. Wild cards replace similar character(s) in a file name, so that the system considers them the same file. The ? wild card replaces one character in a file name; the * wild card replaces several characters. For example, to move files named SUIT123, SUIT456, and SUITABC, type SUIT* Locking File Manager The File Manager is password protected. The first time the File Manager command is selected during a C200MT session, the supervisor password must be entered. File Manager can then be used for the remainder of the C200MT session or until it is locked again. Refer to the C200MT Software Users Guide for more information and the default passwords.
Cutter Information Database (CIDB)

CIDB is an optional database utility which can be used to generate reports for the C200MT program. When this option is enabled, the system automatically inserts information about the marker currently being processed into the Cutter Info database. Reports based on this data can: Be viewed and printed from the C200MT program. Be output automatically to a text file in the C:\REPORT directory. Be accessed using a database program. Include operator comments.
CIDB reports can be viewed onscreen using the Report Generator. For information on using CIDB, refer to the C200MT Software Users Guide. Marker Report Types The following types of Marker reports are available: Partial Marker reports. Marker reports. Shift reports.
Partial Marker Report Partial Marker reports are permanent entries in the CIDB database which can be made before a marker is completely cut. A partial marker report can be: Used to obtain CIDB statistics for cutting that has occurred up to the present, for example, when a shift ends. Requested for any marker that is currently being processed, as long as cutting has not finished.
Marker Reports For each cut file processed on a GERBERcutter with the CIDB option, marker reports are automatically entered in the CIDB database. These reports can be viewed and printed using the Report Generator. Marker reports can also be sent to a text file, MARKERS.RPT. Marker reports include: Prep time (for example, time spent setting the marker origin or opening a cut file). Interrupt time (when the cutter is stopped using the Stop button). Sharpen time. Bite time. Downtime (when the C200MT program is not running).
Shift Reports Shift reports are summary reports derived from individual marker report times for the shift. These reports can be viewed and printed using the Report Generator. A Shift report includes: Interrupt time (when the cutter is stopped using the Stop button). Downtime (when the C200MT program is not running). Percent of operating time and percent of total time for all times reported. Distance totals for the shift as well as their percentage of total distance. Average cut speed and throughput for the shift. Miscellaneous statistics (for example, knife wear and free disk space). Operator comments. System comments (includes all cutter error messages).
52SWLPL]LQJ&XWWHU3HUIRUPDQFH
Differences in fabric and spreads require that adjustments be made to the cutter. This chapter covers procedures that help keep your GERBERcutter running at peak performance. These include: Sharpening and replacing the knife. Setting defaults for knife speeds. Using Knife Intelligence to compensate for lateral force on the knife. Using Path Intelligence to automatically control cutter speed based on knife sharpness, vacuum level, and XY force. Controlling vacuum levels. Setups allow you to set adjustments specifically for differences in fabrics and spreads. For more information about available parameters, refer to the C200MT Software Users Guide.
Note:
Sharpening and Replacing the Knife

The knife blade must be sharp and within wear limits to cut properly. C200MT features provide: Automatic sharpening cycles while cutting. Sharpening when the cutter is idle. Sharpening when installing a new knife. Resetting default knife speeds.
The knife blade is very sharp. See chapter 6 for specific procedures to inspect, adjust, remove, and install a knife blade.
WARNING!
Chapter 5 Optimizing Cutter Performance Page 63
Automatic Sharpening The GERBERcutter provides automatic sharpening cycles which occur while a marker is being cut. Automatic sharpening is controlled by Sharpen parameter settings in the setup. For example, how often a sharpen cycle occurs can be based on cutting distance or piece count. For specific information, refer to the C200MT Software Users Guide. Sharpening When the Cutter is Idle When the cutter is idle, a sharpen cycle can be initiated manually for the current knife or a newlyinstalled knife.
Note:
If you are sharpening a newlyinstalled knife, first use the New Knife command.
To sharpen when cutter is idle
1. Make sure the
knife motor is running.
WARNING!
The knife blade is very sharp. See chapter 6 of this manual for specific procedures to inspect, adjust, remove, and install a knife blade.
2. Do one of the following: Press the Sharpen key on the keyboard.
Press the SHARP button on the beam control panel. 3. In the Sharpen Knife dialog box that displays onscreen, press Enter or click the OK button to accept the defaults for sharpening the current or a new knife. Or you can enter a different number of sharpens. When sharpening is finished, the Knife Wear gauge is reset.
Page 64 Chapter 5 Optimizing Cutter Performance
Resetting for New Knife Your cutter uses knife wear logic to track sharpening cycles for the current knife. This logic, which prompts when the knife wear limit is reached, must be updated whenever a new or partiallyused knife is installed. For information about setting Sharpen parameters which affect knife wear logic, refer to the C200MT Software Users Guide.
To reset for a new knife
1. Carefully install a new or partiallyused knife blade.
WARNING!
2. Turn on the knife motor
3. From the Cutter menu, select New Knife. 4. In the New Knife dialog box, check the appropriate radio button for a Brand New or Used knife. If Used is selected, type the number of times this knife was previously sharpened. 5. Press Enter or click the OK button to reset the Knife Wear gauge.
Note:
After installing a new knife, perform a sharpening cycle (as described on the previous page) before beginning to cut.
Setting Knife Speeds The table below briefly explains knife speeds that can be adjusted for the current session or set as defaults in the setup.
Knife Speed Type Idle Dry Haul/Maximum Cut/Maximum Sharpen Cut Speed=Maximum Use to Set reciprocating speed when the cutter is idle. Set reciprocating speed during dry haul. Set minimum reciprocating speed when cutting. Set maximum reciprocating speed when cutting. Set reciprocating speed during sharpen cycle. Define the relationship between maximum cutting speed and the cutting speed dial on the beam control panel.
To set knife speed defaults, use the Set Knife Speed feature in C200MT. Refer to the C200MT Software Users Guide.
Note:
Make sure that the cutter is in the mode for which you want to set knife speed. For example, the cutter must be at idle to set Idle Knife speed.
Using Knife Intelligence

Knife Intelligence (KI) optimizes cutting performance by: Sensing deflection of the knife (lateral force) caused by cutting difficult materials or high ply spreads. Changing knife angle to compensate for this deflection.
Setup parameters in the Knife and Path Intelligence category define Knife Intelligence for GERBERcutters. Refer to the C200MT Software Users Guide. Knife Intelligence features available in the C200MT program are briefly described below and on the next page. KI Settings Use the Knife Settings command in the Cutter menu to quickly adjust the following parameter settings used to compensate for knife deflection: KI: Gain Controls the amount of force which can be used. KI: Deflection Angle Sets the greatest angle allowable for KI to turn the Caxis.
Nulling Knife Intelligence Sensor Use the Null KI command in the Cutter menu to reset (to zero) Knife Intelligence sensor. This command should be used: When KI is first turned on. Daily after the cutter is initialized (when using KI). For each new spread (when using KI).
To null Knife Intelligence
1. Use the slew buttons on the beam control panel to move the cutter head until the knife blade is just off the edge of the spread. 2. Turn on the knife motor 3. Turn on the vacuum . .
4. Do one of the following: From the Cutter menu, select Null KI. In the KI Warning box, press Enter or click the OK button. Press the
WARNING!
button on the beam control panel twice.

The knife plunges and then rises. The System Messages box prompts when the Null procedure is completed. 5. As needed the KI Calibration diagnostic (see chapter 7) should be used at the beginning of each shift to calibrate the Knife Intelligence deflection voltage sensor.
Using Path Intelligence

Path Intelligence completely or partially controls cut speed using builtin application knowledge and by measuring one or more of the following: Knife sharpness. Vacuum level. XY force.
Setup parameters in the Knife and Path Intelligence category define the Path Intelligence (PI) feature. Settings can only be changed when the cutter is idle. Refer to the C200MT Software Users Guide. Path Intelligence Diagnostics The following diagnostics are available to calibrate for Path: Calibration Use to set up PI and test the current draw of the cutter head and beam. This diagnostic should be used at least once daily and for each new spread. Watch Forces Use to determine the maximum speed setting and number of plies to cut.
Controlling Vacuum Levels

Your GERBERcutter uses vacuum to hold material firmly on the table work surface during cutting. Setup parameters in the Vacuum System category (refer to the C200MT Software Users Guide) define how the cutter: Uses vacuum zoning. Displays vacuum error warnings. Controls vacuum levels and ensures quality cutting; only for cutters equipped with Vacuum Level Control system. Uses the energy savings mode when the cutter is idle. Reports low vacuum levels.
Energy Savings Mode

Note:
The Energy Savings Mode (ESM) parameter must be enabled. Refer to the C200MT Software Users Guide.
To turn on Energy Savings Mode
1. Make sure the vacuum is turned on. 2. From the Cutter menu, select Energy Savings Mode. In the main C200MT control screen, the Vacuum Level gauge label is changed to Energy Savings Mode. 3. Select again to turn off ESM.
S91 Maintenance
60DLQWHQDQFH
This chapter covers preventive maintenance and corrective maintenance procedures for the S91 GERBERcutter. Preventive, or scheduled, maintenance is important because it improves cut quality and extends machine life. Highly technical procedures or those requiring special skills, such as adjusting alignments for the knife and motors, should only be performed by maintenance personnel who have received GERBERcutter training. Otherwise, call your GGT Service Representative. Use the table below or the index for this manual to quickly find maintenance procedures. Illustrations on pages 76 and 77 show assembly locations.
Assembly Head Subassembly cover knife drive train knife sharpener guides and rollers elevator Caxis yaw alignment knife drive alignment/speed adjustment drill bit assembly covers Xaxis gearing and belts scale test Yaxis roundway and squareway gearing and belt scale test work surface cleaner roundways and racks vacuum filters motor and cover Spencer turbine Hoffman blower conveyor and clamp bar lay puller resealer platform and overhead cable Page Number 103 80, 104 106, 170 81, 107 110 80, 86, 112 85, 113 79 80, 86, 97, 113 79, 91, 109, 115 116, 171 81, 87, 92, 97, 118 122 87, 123 89, 127 82, 92, 121, 126 93, 124, 128 89, 127 130 99, 132 82, 133 82, 94, 134 93, 98, 135 93, 98, 136 94, 98, 136 89, 95, 99, 138 95, 99, 140 89, 138 100, 102, 141
Drill Beam
Table
Chapter 6 Maintenance Page 71
Safety Precautions In addition to the safety warnings below, refer to the Safety Precautions chapter at the beginning of this manual.
WARNING!
High voltages exist inside the C200 controller, vacuum and platform electrical enclosure and the cutting table. There are no operatorserviceable parts inside. Only qualified personnel should perform maintenance on these assemblies. Contact your Service Technician in case of a problem. Failure to follow these instructions could cause injury or death.
WARNING!
To avoid serious injury, turn off the C200 controller when instructed. With the main circuit breaker of the C200 controller turned on, power is applied to the cutting table and vacuum generator. Parts could move suddenly.
WARNING!
The origin light on the cutter head uses a Class IIIa laser product which points toward the cutting surface. Never look directly into the laser light source; doing so may cause temporary, or even permanent, damage to your eyes. To avoid potentially harmful reflections, remove all highlyreflective material (such as jewelry) from the cutting surface before turning on the origin light. Turn off the origin light before performing any maintenance on the GERBERcutter.
Page 72 Chapter 6 Maintenance
S91 Maintenance
Maintenance Procedures
Basics The following sections cover basic procedures that need to be performed while maintaining a GERBERcutter. These include:
WARNING!
Removing covers for the head, beam control panel, and end cap. Replacing a knife blade. Inspecting, cleaning, and lubricating head, beam, and table components. Maintaining the table. Cleaning filters for vacuum and stack.
To prevent injury, turn off the main circuit breaker for the cutter before performing maintenance procedures, unless instructed otherwise.
Advanced
CAUTION:
To prevent damage to the cutter and/or fabric, only qualified operators or maintenance personnel who have received GERBERcutter training should perform the following procedures.
In addition, there are advanced procedures that should only be performed by operators or maintenance personnel who have received GERBERcutter training. These procedures are indicated by the above caution and include: Performing sharpener assembly and presser foot maintenance. Checking mechanical alignments, such as heel to heel knife alignment and that the beam is squared. Belt tensioning.
Electrical Procedures requiring electrical drawings are not covered in this manual. Personnel who have received GERBERcutter training should refer to the appropriate Service Manual or Reference drawings for the cutter.
WARNING!
High voltages exist within the vacuum and platform electrical enclosure and inside the C200 controller. Only qualified personnel should perform electrical maintenance procedures. There are no operatorserviceable parts inside.
General Maintenance This section provides hints on performing general cleaning and lubrication for your GERBERcutter. Cleaning In general, use a clean rag to wipe old grease, dirt, and lint away. Denatured alcohol can be applied sparingly with a rag to remove stubborn dirt accumulations. To prevent damage to components made of rubber or to BRISTLE SQUARES, do not use regular alcohol.
Lubrication Apply lubricants sparingly with a clean rag. Use a stiff paint brush to apply multipurpose grease sparingly. Use a grease gun with the appropriate adapter for zerk fittings or a needle tip where indicated. Fill and then wipe away any excess grease.
CAUTION:
Apply all lubricants sparingly. Excess oil or grease can damage fabric. It is better to lubricate lightly and more frequently than it is to apply one heavy coat.
Uses Belt pulley, knife guides, knife blade Sharpener stones Mulitpurpose Swivel assembly Lithiumbased grease Spencer vacuum turbine GGT Part No. 072395000 308010101 596500005 596500006 596002003 596041001
Lubricant/Cleaner GSG44 Loctite Safety Solvent PetroLon Shell Alvania EP2 Fiske Lubriplate Chevron SRI2
Ordering Spare Parts If you find a broken or worn part while performing preventive maintenance, you can order replacement parts through Product Support. For those inside the United States and Canada, call GGT Product Support at 800-999-1448. For those outside the United States and Canada, please call your local Sales and Service office.
Note:
The Service Parts CDROM is a useful tool for identifying parts and part numbers. Ask your local Sales and Service office about availability.
S91 Maintenance
Tools Available from GGT The table below lists tools available from GGT for general maintenance procedures for the S91 GERBERcutter. Specific GGT parts or tools required for a procedure are listed at the beginning of that procedure.
Tool Description screwdriver set socket drive 3/8 in. with 6 in. extension crowfoot attachment 3/8 in. x 7/16 in opening socket set 1/4 in. and 3/8 in. snap ring pliers 90 deg. pliers wrench 1/4 in. wrench 1/2 in. opening 3/16 in. thick open end wrench 5/8 in. to 9/16 in. hex wrench 1/4 in. T-handle hex key set right angle handle hex key set 9-piece open-end combination wrenches spanner wrench spring scale marker pen GGT Part No. 944211601 944582805 945500000 944212801 944003901 944003903 945500005 944012502 944012503 020945000 945500051 944022402 944002401 021513000 945500034 608042001
Note:
This tool list may vary slightly depending on your system configuration.
Additional Tools Additional tools required for basic procedures in this chapter: Clamping pliers. Industrial shop vacuum. Ruler. Step ladder.
For advanced procedures by personnel with GERBERcutter training: Tachometer or strobe light. Feeler gauges.
S91 TCW
Cutter Head Resealer Beam
Clamp Bar
Takeoff End
Operator Side
Beam Control Panel
Surface Cleaner Access Door
Operator Workstation
Front Ramp (Takeon Cover)
Vacuum Filter Drum
Platform Control Panel
Stack (Mast)
Traveling Light Conveyor Work Surface
Front Ramp (Takeon Cover)
Beam
End Cap Cover C200 Controller Panel
Takeon End
Remote Side
Clamp Bar
RSO Platform Panel
Platform Drive Wheel Assembly
S91 Maintenance
S91 Static
Flat Panel
Operator Side
Cutter Head
Operator Workstation Stationary Work Surface
End Cap Cover Beam Left End
Remote Side
S91 ZVC
Beam End Cap Cover Cutter Head Operator Workstation
Conveyor Work Surface
Takeoff End
Beam Control Panel Operator Side
8 Hour Maintenance Schedule
Maintenance Summary and Schedule

The next sections summarize by assembly the preventive and corrective maintenance procedures recommended for your GERBERcutter. Checklists for each maintenance schedule are included in the appendix. 8 Hour Maintenance Schedule In general, eight hour (per shift) maintenance procedures include:
WARNING!
Removing lint buildup from and lubricating components. Cleaning filters. Checking knife alignment. Performing knife sharpener maintenance.
To avoid serious injury, turn off the C200 controller when instructed. With the main circuit breaker for the C200 controller turned on, power is applied to the vacuum and platform control enclosure and cutting table. Parts could move suddenly.
CAUTION:
To prevent damage to the cutter and/or fabric, only qualified operators or maintenance personnel who have received GERBERcutter training should perform the following procedures. Excess oil or grease can damage fabric. Apply sparingly.
CAUTION:
Head
Check knife yaw alignment Use the C Home to System Zero diagnostic. See Chapter 7. Check knife offset alignment Use the Knife Offset Setup diagnostic. See Chapter 7. Check knife intelligence alignment 1. Use KI Null. See Chapter 5. 2. Then use KI Calibration diagnostic to calibrate the KI sensor. See Chapter 7.

Fill the tension arm oil cups (a) 1. Turn off power at the C200 controller and open the head cover. 2. Fill each cup with 10 weight synthetic oil. 3. Wipe clean. Lightly apply 10 weight synthetic oil. Fill the pivot arm oil cup (near b) Same as above.
(a) (b) (c)
Clean and film coat the air cylinder rod (c) for the elevator 1. Turn off power at the C200 controller and open the head cover. 2. Wipe clean. Lightly apply 10 weight synthetic oil. Clean and film coat the two elevator guide rods (d) Same as above.
(f)
(g)
Head Knife Drive Train

1. Turn off power at the C200 controller and open the head cover. 2. Follow the procedures for removing and inspecting the knife drive train beginning on page 104. Clean and lubricate swivel assembly 1. Use the swivel lube kit to fill the lubrication hole (e) in the swivel assembly with grease. Wipe away any excess. 2. Lightly apply multipurpose grease to the outside of the swivel assembly before installing in the cutter tube. Clean and lubricate knife articulating arm (f) Wipe away old grease. Lightly apply multipurpose grease. Clean and lubricate cutter tube (g) 1. Wipe out old grease. 2. Lightly apply multipurpose grease to the inside of the cutter tube. Reassemble 1. Follow the assembly procedures on page 104. 2. Then check bristle penetration on page 112.
(d)
(e)

Head Sharpener Assembly
Turn off power at the C200 controller and open the head cover. Perform sharpener assembly maintenance and knife blade alignment, as necessary Follow the procedure on page 107. Clean and film coat the knife presser foot slide rod (a) and rod guide (b) Wipe clean. Lightly apply 10 weight synthetic oil.
(c) (a) (b)
Clean and film coat the air cylinder rod for the knife presser foot 1. Reduce air pressure to the head. Lower the air cylinder (c). 2. Wipe clean. Lightly apply 10 weight synthetic oil. Perform knife guide alignment, as required Follow the procedure on page 110.
Drill
Turn off power at the C200 controller. Clean and film coat the up/down air cylinders (a) for each drill unit 1. Reduce air pressure to the head. Lower the drill unit to access the two air cylinder rods. 2. Wipe clean. Lightly apply 10 weight synthetic oil. 3. Repeat for the auxiliary drill, if available. Clean and film coat the air cylinder rods (b) for the drill presser foot
(b) (a)
1. Reduce air pressure to the head. Lower the presser foot. 2. Wipe clean. Lightly apply 10 weight synthetic oil.
Beam
Inspect, clean, and film coat the Yaxis roundway (a) 1. Turn off power at the C200 controller. 2. Check for scratches, nicks, and gouges which can damage bearings. If found, contact Field Service. 3. Check for debris. Wipe clean. Lightly apply 10 weight synthetic oil. Clean and film coat the Yaxis squareway (b) 1. Turn off power at the C200 controller. 2. Wipe clean. Lightly apply 10 weight synthetic oil.
(b)
Table
(a)
Inspect, clean, and film coat the Xaxis roundways (c) 1. Turn off power at the C200 controller. 2. Check for abrasions or scoring. If found, contact Field Service. 3. Check for debris. Wipe clean. Lightly apply 10 weight synthetic oil. Inspect the Xaxis racks (d) 1. Turn off power at the C200 controller. 2. Check for damaged teeth, scoring or abrasion. If found, contact Field Service. 3. Check for excess debris and wipe away.
(d) (c)
Table Vacuum
Clean the vacuum intake filter 1. Turn off power at the C200 controller. For Static and ZVC systems, turn off power at the external vacuum assembly. 2. Remove the nut and bolt and then the retaining ring. Remove the cover (indicated). 3. Remove the wing nut and then remove the screens and filter. Vacuum the filter, screens, and inside of the drum. Soak the filter, if necessary. 4. Reinstall the filter and cover.

(a)
Table Vacuum (contd.)

Check for fluid in air/reducer filters 1. Turn off power at the C200 controller. For Static and ZVC systems, turn off power at the external vacuum assembly. 2. Take note of the air pressure setting. For each of two filters, turn the top cap (a) to reduce air pressure before proceeding. 3. Loosen the drain plug (b) at the bottom of the filter. 4. Allow any fluid to drain out. 5. Retighten the drain plug and reset the air pressure.
(b)
40 Hour Maintenance Schedule Depending on the number of shifts required by your production schedule, the following maintenance procedures need to be performed at least once and possibly three times per week. These procedures include:
WARNING!
Cleaning, lubricating, and checking X, Y, and Caxis gears. Checking drive belt tension. Checking head stops.
To prevent injury, turn off the main circuit breaker for the C200 controller before performing maintenance procedures, unless instructed otherwise.
CAUTION:
CAUTION:
Head Caxis Drive

Check Caxis drive belt (a) 1. Turn off power at the C200 controller and open the head cover. 2. Check for wear or damage. To prevent slippage, the belt must be wiped free of any grease. 3. Check belt tension. There should be approx. 6 or 7 mm (1/4 in.) deflection at the center of the belt. Replace the belt, if needed. See page 113.
(b)
Clean, lubricate, and check Caxis servo gearing (b) 1. Turn off power at the C200 controller and open the head cover. 2. Wipe away old grease. Check for wear and damaged teeth. 3. Lightly apply multipurpose grease.
(a)
Head Knife Drive

Check tension of knife drive belts 1. Turn off power at the C200 controller and open the head cover. 2. Check for belt wear or damage. To prevent slippage, the belt must be wiped free of any grease. Replace the belt, if needed. 3. Check belt tension. Adjust, if needed. See page 114. Check mechanical alignment of the knife 1. Use the Heel to Heel Cut Test diagnostic along with the knife alignment box. See chapter 7. 2. Adjust mechanical knife offset, if needed. See page 111. Check head upper stop 1. Turn off power at the C200 controller and open the head cover. 2. With the head assembly up (as shown), set the flywheel (a) at the top of its stroke (TDC). 3. Adjust the upper stop (b) until the corner edge of the knife blade is in the middle of the lower grinding wheel (shown). Check head lower stop 1. Remove air pressure from the head. With the head assembly down (not shown), set the flywheel (a) at TDC. 2. Adjust the lower stop (c) until the tip of the knife blade penetrates the bristle to proper depth. See below. Flywheel Stroke 13/16 in. 1 in. Chopping set @ BDC Depth 1/8 in. (3.2 mm) 1/16 in. (1.6 mm) 3/8 in. (9.3 mm)
Corner Edge Grinding Wheel (b) (a)
(c)
Table Surface
Drill
Check the drill belt(s) 1. Turn off power at the C200 controller and remove the drill motor cover (indicated). 2. Check for belt wear or damage. To prevent slippage, the belt must be wiped free of any grease. Replace the belt, if needed. 3. Check belt tension. Adjust, if needed. See page 118.
Beam X and Yaxes Gearing

Clean, lubricate, and check first Xaxis pinion gearing (a) 1. Turn off power at the C200 controller. Remove the beam control panel cover. 2. Wipe clean and check gears for nicks. Check for a slight amount of backlash between gearing. Note: Check in several places in case there are any high spots in the gears or racks. 3. Lightly apply multipurpose grease. Clean, lubricate, and check first Xaxis servo gearing (b) Same as above. Clean, lubricate, and check Yaxis countershaft gearing (c)
(g)
(b)
(a)
(c)
(d)
Same as above. Clean, lubricate, and check Yaxis servo gearing (d) Same as above. Clean, lubricate, and check second Xaxis pinion gearing (e in both views)
(e) (g)
1. Turn off power at the C200 controller. Remove the end cap cover. 2. Wipe clean and check gears for nicks. Check for a slight amount of backlash between gearing. Note: Check in several places in case there are any high spots in the gears or racks. 3. Lightly apply multipurpose grease. Clean, lubricate, and check second Xaxis servo gearing (f) Same as above.
(f) (e)

Beam X and Yaxes Gearing (contd.)
Check the torque tube drive belts (g on previous page) 1. Turn off power at the C200 controller. Remove the beam control panel and end cap covers. 2. At both sides of the beam, check for wear or damage. To prevent slippage, the belts must be wiped free of any grease. Replace the belt(s), if needed. 3. Check belt tension. Adjust, if needed. See page 123. Clean, lubricate, and check wheel housing cam rollers 1. Turn off power at the C200 controller. Remove the beam control panel cover as needed to access zerk fittings. 2. Find four cam rollers (a) on the beam control side of the cutter (two shown; two on the squareway side of the beam). 3. Check for any binding against the roundway when moving the beam along the full length of the table. Adjust cam rollers, if needed. See page 125. 4. Fill zerk fittings on each cam roller with multipurpose grease. Clean and lubricate first Xaxis wheel assembly 1. Turn off power at the C200 controller. Remove the beam control panel cover cover as needed to access zerk fittings. 2. Find zerk fittings on two wheel assemblies (b), one shown. Fill with multipurpose grease. Clean and lubricate second Xaxis wheel assembly 1. Turn off power at the C200 controller. Remove the end cap cover as needed to access zerk fittings. 2. Find zerk fittings for two wheel assemblies (c), one shown from the back. Fill with multipurpose grease.
(c) (a)
(a)
(b)
Beam X and Yaxes Gearing (contd.)

Perform Xaxis spring scale test See procedure on page 127. Perform Yaxis spring scale test See procedure on page 127. Bite Encoder for TCW
Beam Bite Encoder

Clean and inspect bite encoder wheel (TCW and ZVC) 1. Turn off power at the C200 controller. 2. Check that the grit on the encoder wheel is not worn away. 3. Remove any plastic that might be wrapped around the wheel. 4. Tighten the set screw on the collar, as needed. Check that the wheel remains positioned directly over the bite indicator strip(s) along the edge of the cutting table. Bite Encoder for ZVC
Table Clamp Bar (TCW)

Clean and film coat the clamp bar air cylinders 1. With power on, lower the clamp (shown in up position). 2. Wipe away debris from two air cylinder rods. Lightly apply 10 weight synthetic oil.
Table Resealer Option (TCW)

Clean and film coat the resealer air cylinder rods 1. With power on, run the Input Output Test (DG 23) diagnostic. See chapter 7. 2. Raise the resealer bar (a). 3. Wipe away debris from the air cylinder rods, one located in each end post (b). Lightly apply 10 weight synthetic oil. Check resealer bar up/down air flow adjustment 1. Raise and lower the resealer bar, checking for even motion. 2. If up or down motion is uneven, adjust air flow by turning the adjustment screw (c) on the hose connector for each air cylinder.
(b) (c)
(a)
160 Hour Maintenance Schedule Depending on the number of shifts required by your production schedule, the following maintenance procedures need to be performed three to six times yearly. These procedures include: Running diagnostics to check knife or drill speed and that the beam is square. Checking beam bearings. Checking table and vacuum components.
WARNING!
CAUTION:
CAUTION:
Head
Check knife speed adjustment (should be OK for one year) 1. With the power on, use the Parameter Manager to set a low knife speed. 2. Run the Input Output Test (DG23) diagnostic to enable the knife drive. See chapter 7. Use a tachometer or strobe light to verify the low speed setting. 3. If necessary, adjust the Zero and Max potentiometers on the knife drive board.
4. page 115.
See adjustment procedure and warnings on
5. Repeat steps 1 through 4, setting and verifying a high knife speed setting.
Drill
Check drill speed adjustment for each drill unit (should be OK for one year) 1. With the power on, use the Parameter Manager to set a low drill speed. 2. Run the Input Output Test (DG23) diagnostic to enable the drill drive. See chapter 7. Use a tachometer or strobe light to verify the low speed setting. 3. If necessary, adjust the Zero and Max potentiometers on the drill drive board.
4. page 119.
See adjustment procedure and warnings on
5. Repeat steps 1 through 4, setting and verifying a high drill speed setting. 6. Repeat for the auxiliary drill, if available.
Beam Yaxis
Check Yaxis roundway bearings 1. Turn off power at the C200 controller. 2. Attempt to physically move the cutter head from side to side. If you notice movement, adjust the roundway bearings (a). See page 126. 3. Note: There should be no binding on the Yaxis. Check Yaxis squareway bearings 1. Turn off power at the C200 controller. 2. Attempt to move the cutter head up and down. If you notice movement, adjust the squareway bearings (b). See page 126. 3. Note: There should be no binding on the Yaxis.
(a)
(b)
Beam Yaxis (contd.)

Check Yaxis belt 1. Turn off power at the C200 controller. 2. Push the cutter head toward the operator workstation. 3. Check the belt for signs of wear or fraying. Replace if damaged. 4. Check belt tension by inserting several fingers under the belt at a location approx. 60 cm (2 ft.) from the end cap cover. You should be able to raise the belt 2.5 to 3.8 cm (1 to 1 1/2 in.) only. 5. Adjust the tension, if needed. See page 128. Check if beam is square 1. Run the Beam Square Test diagnostic. See chapter 7. 2. Square the beam, if needed. See page 129.
Table Vacuum
Check vacuum generator belts (Spencer turbine) 1. Turn off power at the C200 controller. For Static and ZVC systems, turn off power at the external vacuum assembly and at the table control or lay puller panel. 2. For TCW systems, remove front ramp. For Static and ZVC systems, remove the jack shaft cover. 3. Check the belt(s) for wear or fraying. Replace all belts, even if only one is damaged. 4. Check belt tension by depressing the center of the belt(s) between the vacuum motor and vacuum turbine. Compare the deflection amount with manufacturing specs. 5. To adjust or replace the belt(s), see page 136.

Check vacuum generator belts (Hoffman blower with pillow block assembly) 1. Turn off power at the C200 controller. Turn off power at the external vacuum assembly and at the table control or lay puller panel. 2. Check the belt(s) for wear or fraying. Replace if damaged. 3. Check belt tension by depressing the center of the belt between the vacuum motor and the pillow blocks. Compare the deflection amount with manufacturing specs. 4. To adjust or replace the belt(s), see page 136. Clean vacuum stack filter 1. Turn off power at the C200 controller. For Static and ZVC systems, turn off power at the external vacuum assembly and at the table control or lay puller panel. 2. Use a step ladder to reach the stack. 3. Remove the wing nut and then the filter and screens from the top of the vacuum stack filter. 4. Clean the filter by soaking. 5. Reinstall or replace, if needed.
Table Material Handling (TCW and ZVC)

Check conveyor drive alignment 1. Place a typical production spread on the spreading table. 2. At the Platform control panel (TCW shown), set the Conveyor Mode to Manual. 3. Jog the conveyor. 4. If the conveyor movement is not satisfactory or the motor growls for too long before the conveyor begins moving, adjust potentiometers on the drive board.
5.
See warnings and procedure on page 139. See also the documentation for the conveyor drive.
Table Material Handling (Static)

Check lay puller drive alignment 1. Position a typical production spread in the lay puller. 2. Jog the lay puller. 3. If the lay puller movement is not satisfactory or the motor growls for too long before the lay puller begins moving, adjust potentiometers on the drive board.
4.
See warnings and procedure on page 140.
960 Hour Maintenance Schedule Depending on the number of shifts required by your production schedule, the following maintenance procedures need to be performed two to three times yearly. These procedures include:
WARNING!
Checking knife and drill motor bushings. Checking fluid levels of gear boxes for conveyor and surface cleaner. Cleaning and lubricating platform components. Lubricating vacuum motor and turbine/blower. Checking overhead cable trolley.
CAUTION:
CAUTION:
Head
Check knife drive motor brushes 1. Turn power off at the C200 controller. 2. Remove two bushing caps (one shown) to gain access to the motor brushes. 3. Check for excessive wear. Replace the brushes and caps, as needed. See page 115.
Drill
Check drill motor brushes 1. Turn power off at the C200 controller. Remove the drill drive motor cover (indicated). 2. Remove two caps to gain access to the motor brushes. 3. Check for excessive wear. Replace the brushes and caps, as needed. See page 119.
Table Vacuum
Lubricate Baldor vacuum motor 1. Turn power off at the C200 controller. For Static and ZVC systems, also turn off power at the external vacuum assembly and at the table control or lay puller panel. 2. Remove the front ramp for TCW only. Find two zerk fittings on the vacuum motor (indicated). 3. Fill with lithiumbased grease. Lubricate Spencer vacuum turbine (Required more often for extreme ambient temperatures, bearing temperatures of 120 to 170 deg F, and in very dirty operating conditions; required less often for intermittent operation.) 1. With the front ramp removed (TCW only), find two fill cups on the vacuum turbine (indicated). 2. Insert a clean, metal probe into each cup several times to a depth of 35 mm (1 1/2 in.). 3. Remove the probe and fill with Chevron SRI #2 grease. 4. Repeat insertion of probe and filling with grease three or four times. Lubricate Hoffman blower (a) (should be OK for 1800 to 2000 hours) 1. Turn power off at the C200 controller. Also, turn off power at the external vacuum assembly and at the table control or lay puller panel. 2. At the end of the blower, open the top and bottom plugs (not shown). 3. Insert a metal rod through the top plug opening and push old grease out of the bottom plug opening. 4. Fill from the top with Chevron SRI #2 grease until clean grease comes out of the bottom plug. Replace the plugs.
Motor
Turbine
External Vacuum System with Blower

(b)
(a)
Lubricate pillow blocks (not shown) 1. Depending on the setup of the external system, find zerk fittings on two pillow blocks. 2. Fill with lithiumbased grease.

Check Hoffman coupling alignment 1. Turn power off at the C200 controller. Also, turn off power at the external vacuum assembly and at the table control or lay puller panel. 2. Remove the coupling guard (b on previous page). 3. Use hot system method to check coupling alignment. See page 137. 4. Use cold system method to adjust alignment. See page 137.
Table Material Handling (TCW and ZVC)

Check fluid level of conveyor gear box (change every third time) 1. Turn power off at the C200 controller. 2. For TCW systems, remove the front ramp and several slats to gain access to the gear box. For ZVC systems, remove the takeon cover. 3. Remove the fill screw from the gear box. Check the oil level. 4. As required, add SAE 600 weight oil to the center line of the shaft.
Table Material Handling (Static)

Check fluid level of lay puller gear box (change every third time) 1. Turn power off at the C200 controller. 2. Remove the oil level plug at the side of the gear box. Check the oil level. 3. As needed, add SAE 600 weight oil through the vent fitting up to the oil level fitting.
Table Surface Cleaner (TCW)

Check fluid level of surface cleaner gear box (change every third time) 1. Turn power off at the C200 controller. 2. Remove the cover (a) for the gear box. 3. Remove the fill screw on top of the gear box and check the fluid level. 4. As required, add SAE 600 weight oil to the level indicated on the side of the gear box. Lubricate surface cleaner pillow block bearings 1. Turn power off at the C200 controller. 2. Open each access door (b in both views) at the takeoff end of the cutter. 3. Using a flashlight, locate each of two pillow block bearings, one on opposite sides of the cutter (c in both views indicates general location). 4. Each bearing has a zerk fitting. Fill with multipurpose grease.
(c) (b) (a) (b) (c)
Table Platform Drive (TCW)

Clean and lubricate platform drive chain 1. Turn power off at the C200 controller. Also, turn off power to the table control panel. 2. Remove round black plates, two located on the remote side (d one shown) and one located on the operator side of the cutter behind the GERBERcutter name panel. 3. Lighly apply multipurpose grease to the chain. 4. Manually reposition the chain, as needed to complete the job. Lubricate platform drive sprocket bearings 1. Turn power off at the C200 controller. Also, turn off power to the table control panel. 2. Locate four zerk fittings on the sides of the cutter as shown at right. 3. Fill with multipurpose grease.
Location of drive sprocket zerk fittings on cutter
(d)
Table Platform Drive (contd.)

Lubricate platform drive cam roller bearings 1. Turn power off at the C200 controller. Also, turn off power to the table control panel. 2. Remove the front ramp and several slats to gain access to two cam roller bearings, each with one zerk fitting. 3. Fill with multipurpose grease. Check fluid level of platform drive gear box (change every third time) 1. Turn power off at the C200 controller. Also, turn off power to the table control panel. 2. On each side of the cutter, remove covers over the platform drive wheel assemblies (a). 3. Remove the fill screw from the gear box. Check the level. 4. As required, add SAE 600 weight oil to the center of the shaft. Lubricate platform drive shaft bearings 1. Turn power off at the C200 controller. Also, turn off power to the table control panel. 2. On the remote side of the cutter, remove the cover from the platform drive wheel assembly. On the operator side of the cutter, find the access holes. 3. Fill zerk fittings on each drive shaft with multipurpose grease (four fittings total). Lubricate platform wheel cam roller bearings 1. Turn power off at the C200 controller. Also, turn off power to the table control panel. 2. Find the access holes (b) in the covers for the platform drive wheel assemblies, one assembly on each side of the cutter at the takeoff end. 3. Fill zerk fittings on each wheel cam roller bearing with multipurpose grease (four fittings total).
(b) (a)
Table Overhead Cable Trolley (TCW)

Check roller and clamps for overhead cable trolley 1. Turn power off at the C200 controller. Also, turn off power to the table control panel. 2. Wipe roller bearings clean. 3. Lubricate sparingly with multipurpose grease.
Cover Maintenance
Cover The cover encloses the cutter head. It is a twopiece unit that protects the cutter head components from damage and the operator from injury.
Open/Remove
Cutter Head
The cutter head contains the knife and performs the actual cutting of material. It moves across the cutting table on the beam.
Knife Drive Elevator Assembly
1. Turn off power at the C200 controller.
WARNING!
Knife Drive Train Cutter Tube Sharpener Assembly
Caxis Motor
2. Lift to open (or raise) the front cover section. 3. If it is necessary to remove the front and back sections of the cover: a) Remove all screws that attach the back cover section to the frame. b) Slide the two cover pieces up and off the cutter head.
WARNING! Do not routinely operate the GERBERcutter without the cutter head covers; this could cause injury.
Cutter head assemblies covered in this section are listed in the table below.
Assembly Cover Knife Drive Train Knife Sharpener Assembly Knife Guides and Offset Elevator Caxis Drive Knife Drive See Page 103 104 106 107 109 112 113 113
Install/Close
1. If the front and rear sections of the cover were removed: a) Slide the two cover pieces over the cutter head so that they rest in the groove of the cutter head. b) Replace and tighten all screws that attach the back cover section to the frame.
Knife Drive Train Maintenance

2. Lower and close the front head cover.
Inspect
3. If you are through with maintenance, Turn on power at the C200 controller.
1. Wipe away old grease from the: Articulating arm. Inside of the cutting tube.
Knife Drive Train The knife drive train moves the knife and works with the Caxis gear to let the knife cut corners, notches, curves, and other complex shapes. The drive train is comprised of a flywheel, connecting rod, pivot block, swivel link, swivel assembly, and knife. Maintenance procedures related to this part of the cutter are covered in the 8 hour maintenance schedule.
Swivel assembly. 2. Inspect the swivel assembly for gouges, cracks, and other damage. Rotate the stem of the swivel assembly several times to check for binding. If there are any defects or the stem binds, replace the assembly.
Flywheel Screw 1 Connecting Rod Pivot Block and Articulating Arm
WARNING!
The knife is very sharp. To prevent personal injury, exercise care in handling the knife during any maintenance procedure.
Screw 2
Swivel Link
Remove
1. Turn off power at the C200 controller. 2. Open the cutter head cover. 3. Remove screw 2 which fastens the swivel link to the pivot block and articulating arm. 4. Lower the swivel link into the cutter tube (see previous page). 5. Disconnect the connecting rod from the flywheel by removing screw 1. 6. Pull the swivel link, swivel assembly, and knife out of the cutter tube.
Knife Swivel Assembly
Knife Drive Train Maintenance

6. Check the knife penetration into the bristle. See page 112.
CAUTION:
Required Supplies swivel lube kit EP2 lubricant Lubricate
GGT Part No. 031154000 596500006
Always check bristle penetration when you install a new knife. Failure to check the depth of bristle penetration can damage the work surface.
1. Using the grease gun with the 0.050 in. needle installed, inject grease into the lubrication hole of the swivel until it starts to seep out around the stem. Wipe off excess grease.
Lubrication Hole
7. Check knife operation: a) At the beam control panel, set the knife switch to ON. b) Check that the knife moves smoothly with no unusual noise. If you notice any problems, call your service representative. c) At the beam control panel, set the knife switch to OFF. 8. At the operator workstation, use the New Knife command in the Cutter menu to reset the knife wear logic. 9. Execute several sharpening cycles by pressing the SHARP button on the beam control panel.
CAUTION:
Excess lubricants can damage fabric. Apply sparingly.
2. Using multipurpose grease, lightly coat the: Outside of the swivel assembly. Inside of the cutter tube. Pivot block of the articulating arm assembly.
Install
WARNING!
1. Insert the swivel link, swivel assembly, and knife into the cutter tube. 2. Fasten the connecting rod to the flywheel with screw 1. 3. Reposition the articulating arm. Fasten the swivel link to the pivot block and bushing assembly with screw 2. 4. Lower and close the front head cover. 5. Turn on power at the C200 controller and run the C200 program.
Knife Maintenance
Knife The knife is the part of the cutter head that actually cuts the material. It is attached to the lower end of the knife drive train. Good cut quality depends on a properly sharpened, undamaged knife.
Install Note:
Knife sizes and types are available for different applications. See the table on page 170. If you are unsure about the size or type of knife in your system, contact Field Service.
WARNING!
1. Inspect the new knife for flaws before installing it. 2. Slide the knife into the swivel assembly. 3. Install screw 1, but do not tighten it. Notice that the hole is offset to prevent installing the knife backwards. 4. While holding the knife and swivel link, place against a firm surface and push down on the knife and swivel. Tighten screw 1. Or, hold as shown below. While maintaining the pressure, have an assistant tighten screw 1. This seats the back of the knife in the back of the swivel assembly.
Inspect
1. Turn off power at the C200 controller. 2. Check the knife for excessive wear and improper sharpening.
Good
Unacceptable
3. If necessary, install a new knife.

Remove
5. Install the knife drive train. 1. Turn off power at the C200 controller. 6. Check bristle penetration. See page 112. 2. Open the cutter head cover.
CAUTION:
3. Remove the knife drive train (see page 104). 4. Remove screw 1 that fastens the knife to the swivel assembly. 5. Slide the old knife out of the swivel assembly.
Always check bristle penetration when you install a new knife. Failure to check the depth of bristle penetration can damage the work surface.
7. If you are through with maintenance: a) Lower and close the front head cover.
Sharpener Assembly Maintenance

b) Turn on power at the C200 controller. Sharpener Assembly Sharpener maintenance is critical to cutter performance, because it keeps the knife sharp. A dull knife causes material fusing and poor performance. Worn or dirty grinding wheels can cause uneven sharpening. Procedures in this section are included in the 8 hour maintenance schedule. Grinding wheel mesh varies according to application and size and type of knife. Contact your Field Service representative for more information.
Presser Foot Bowl Shaft Locations
CAUTION:
Inspect
1. Use the checklist below as you remove and disassemble the sharpener assembly.
Note:
'
Part sharpener assembly KI connectors and cable grinding wheel pulley drive belts (O-rings) yoke arms grinding wheels latch spring and clamp presser foot bowl shafts upper knife guide lower knife guide and rollers
Check For dirt and lint buildup damaged cable or loose connectors cracks, stretching, or oil deposits excessive play on the pinion wheel shaft deterioration and particle buildup bends, wear, or other damage scratches, nicks, or gouges any damage scratches, nicks, or gouges
Cutter Tube Location
Latch Spring Clamp Upper Pulley
Yoke Arms
Spring Grinding Wheel Assembly
2. If you see any of the conditions described above, replace the appropriate part. If you are unsure why the damage resulted, call your Field Service representative before replacing.
Sharpener Assembly Maintenance

Disassemble Remove
1. Turn off power at the C200 controller. 2. Open the cutter head cover. 3. Remove the knife drive train (see page 104). 4. Pull the swivel link, swivel assembly, and knife out of the cutter tube. 5. Unplug the two connectors for the Knife Intelligence (KI) transducer. 6. Loosen the mounting screw (shown below) that holds the sharpener assembly on the cutter tube. 7. Lower the sharpener assembly and remove it from the cutter head.
1. Remove the foot spring (shown on previous page). 2. Remove the presser foot bowl assembly. 3. Remove the latch spring clamp. 4. Stretch the grinding wheel pulley belts over each pulley. Then slide the pulleys out of the yoke arms.
Clean and Lubricate Required Supplies Loctite Safety Solvent grinding wheel (60 mesh) grinding wheel (80 mesh) grinding wheel (100 mesh) belt, pulley (O-ring) CAUTION: GGT Part No. 308010101 036779000 020505000 036779001 496500215
Do not spray solvent near KI connector.
Mounting Screw KI Connector Wire
1. Using a clean cloth and either denatured alcohol or Loctite solvent, clean: Inside the cutter tube. Grinding wheels (replace if worn). Grinding pulley belts. Upper knife guide. Presser foot bowl shafts. Air cylinder rod.
Air Cylinder Rod
Presser Foot Bowl
2. Using a clean rag dampened with SAE 10 oil, lubricate the presser foot bowl shafts and air cylinder rod.
CAUTION:
Excess lubricants can damage fabric. Apply sparingly.
Knife Guides and Offset Maintenance

Assemble
1. Install the grinding wheels and grinding pulley belts on the yoke arms.
Note:
9. Remove the knife drive train. 10. Inspect the grinding pattern in the ink on the knife. It should be equal on both sides and extend from the cutting edge back. It also should extend from the heel of the blade to about 100 mm (4 in.) above the heel. If the pattern is not acceptable, call your service representative. If the pattern is acceptable, install the knife drive train. 11. If you are through with maintenance: a) Lower and close the front head cover. b) Turn on power at the C200 controller.
You should keep a spare set of grinding wheels. When you need to change the grinding wheels, replace them with the spare set and resume cutting.
2. Install the latch spring clamp. 3. Install the presser foot bowl assembly. 4. Install the foot spring.
Install
1. Place the sharpener assembly onto the cutter tube. Tighten screw 1 that holds the sharpener assembly on this tube. 2. Plug in the KI connectors. 3. Coat both sides of the knife with ink from a black marker with a broad tip.
Knife Guides and Offset Alignment of the upper and lower knife guides must be done whenever you replace components in the sharpener assembly that affect knife guide alignment. These include the upper or lower knife guides and rollers in the presser foot.
Lower Guide Rollers
WARNING!
4. Install the knife drive train. See page 106. 5. Turn on power at the C200 controller and run the C200MT program. 6. On the beam control panel, set the knife switch to ON. 7. Execute 10 sharpening cycles by pressing the SHARP button on the beam control panel.
Presser Foot

3. Check the knife blade alignment as follows: a) Hold the sharpener assembly horizontally in one hand and pull the presser foot bowl away from the sharpener assembly approximately 100 mm (4 in.). b) Guide a knife through the upper guide, making sure the back of the knife fully contacts all three runners in the upper guide (shown at top left). Check that back of the knife blade just contacts the rear roller of the lower guide. c) If the knife blade does not align correctly, shims placed in the upper guide may correct the alignment. The shim material used is a laminated 1/32 in. round washer made up of numerous layers of brass shim stock 0.002 in. thick. To adjust shim thickness, you can separate these layers with a pocket knife.
Note:
Back of blade must contact all 3 runners flatly.
Upper knife guide Sharpener housing Correct alignment is when the back of the blade contacts roller.
Rear roller of lower guide
Make sure all parts are in spec. Shimming may not be possible in this case.
Shim these points between the upper guide and sharpener housing.
Knife Guides
Align
1. Turn off power at the C200 controller. 2. Remove the knife drive train and the sharpener assembly. See pages 104 and 108. Appropriately placed shims should remain in place until either the upper or lower guide is replaced.
WARNING!
4. Install the sharpener assembly and knife drive train. 5. Make sure that the knife blade moves freely through the cutter tube and sharpener assembly. 6. If you are through with maintenance: a) Lower and close the front head cover. b) Turn on power at the C200 controller.

If the pattern looks like (b), loosen the 270 degree screw and tighten the 90 degree screw. 4. To correct the heeltoheel measurement, loosen the 90 degree and 270 degree positioning screws. Then adjust the 0 and 180 degree positioning screws as follows: If the measurement was greater than the spec, loosen the 180 degree screw and tighten the 0 degree screw. If the measurement was less than the spec, loosen the 0 degree screw and tighten the 180 degree screw. 5. When adjusted, tighten the top four cutter block locking screws and at least two of the bottom four cutter tube locking screws. 6. Turn on power at the C200 controller. 7. Run the Heel to Heel Test diagnostic again to check knife alignment. If additional alignment is required, repeat steps 3 through 6 as needed. 8. When the knife has been adjusted correctly, tighten the 90 and 270 degree positioning screws and all locking screws.
Note:
Knife Offset The knife should produce a cut pattern that can be aligned heeltoheel as shown below with the correct distance measurement.
Inspect Required Supplies knife alignment box GGT Part No. 027014000
1. Place the knife alignment box on the table and cover with plastic. Apply vacuum. 2. Run the Heel to Heel Test diagnostic. See chapter 7. 3. If either the cut pattern is unacceptable or the measurement is not within 12.7 to 14.3 mm (0.5 to 0.56 in.), align as explained below.
Measurement
(a)
(b)
Good
Unacceptable
Alignment
1. Turn off power at the C200 controller and open the cutter head cover. 2. Loosen the four cutter block locking screws. Lower the presser foot bowl and loosen the four cutter tube locking bolts. 3. To correct the cut pattern, loosen the 0 degree and 180 degree positioning screws. Then adjust the 90 and 270 degree positioning screws as follows: If the pattern looks like (a) shown above, loosen the 90 degree screw and tighten the 270 degree screw.
Be careful not to over tighten the positioning screws. These are meant to be used for adjustment only, and not to secure the cutting block.
180 Degree Screw Location
Cutter Block Locking Screw 90 Degree Screw Location
Elevator Maintenance
Elevator The elevator assembly is the frame that supports the knife drive gear, the knife drive train, and the cutter tube. The elevator assembly rides up and down on two guide rods. The air cylinder rod connects the elevator assembly to the air cylinder piston. As the piston moves through the air cylinder it moves the rod. The rod in turn moves the elevator assembly. The rods on which the elevator assembly moves up and down must be kept free of dirt and grit so that the elevator assembly rides smoothly. Elevator Guide Rods Check the guide rods for scratches, nicks, and gouges. These defects can damage the bearings in the elevator assembly. If you see any of these conditions, call Field Service immediately. Air Cylinder Rod Check the two elevator guide rods for scratches, nicks, and gouges. These defects can damage the bearings in the elevator assembly. If you see any of these conditions, call Field Service immediately. Maintenance procedures related to this part of the cutter are covered in the 8 hour maintenance schedule. Head Stops To prevent knife damage to the bristle work surface, elevator head stops limit the up and down travel of the elevator. After checking bristle penetration, the upper and lower head stops are adjusted. Check and make all adjustments with the flywheel at top dead center (TDC). Exception is for the chopping stroke, which is adjusted at BDC.
Elevator Assembly
Bristle penetration refers to how far the knife goes into the bristle. The correct distance is related to the flywheel stroke as shown in the table below.
CAUTION:
To prevent damage to the bristle work surface, always check the adjustment for bristle penetration after installing a new knife.
Depth 3.2 mm (1/8 in.) 1.6 mm (1/16 in.) 9.3 mm (3/8 in.)
Flywheel Stroke 13/16 in. 1 in. Chopping set @BDC
Maintenance procedures related to this part of the cutter are covered in the 40 hour maintenance schedule.
Knife Drive Head Upper Stop
Head Lower Stop
Caxis Drive Maintenance

Caxis Drive The Caxis drive belt links the knife drive servo gear to the knife drive train. The drive belts and gears must be in good condition for the best cutting performance. Servo Gear Check for wear and damaged teeth. Look for excessive oil or grease on the gear. Call your Field Service representative if any of these conditions exist. Drive Belt Check for wear or damage. To prevent slippage, wipe the belt free of any grease or oil. Belt deflection should be 6 or 7 mm (1/4 in.) at the center of the belt. Replace, if needed. Maintenance procedures related to this part of the cutter are covered in the 40 hour maintenance schedule.
Adjust/Replace Required Supplies belt, Caxis GGT Part No. 180138037
Upper Drive Belt
6. If you are through with maintenance: a) Lower and close the front head cover. b) Turn on power at the C200 controller.
Knife Drive Knife drive belts connect the knife drive motor to the knife crankshaft through a series of pulleys. As the knife drive motor turns, the drive belts transfer motion to the knife crankshaft. The circular crankshaft motion is translated to up and down knife motion by the articulating arm assembly. Tension and Pivot Arm Oil Cups Fill the two tension arm oil cups and the pivot arm oil cup. Maintenance procedures related to this part of the cutter are covered in the 8 hour maintenance schedule.
1. Turn off power at the C200 controller. 2. Open the cutter head cover. 3. Loosen three mounting screws on the Caxis motor. Sliding the knife motor away from the knife drive train tightens the drive belt. Sliding it towards the knife drive train loosens the drive belt. 4. If needed, replace the belt. 5. Tighten the mounting screws and check the drive belt tension again. Repeat the tensioning procedure, as needed.
Upper Tensioning Bar Mount Drive Motor Mounting Plate Lower Drive Belt
Caxis Drive Caxis Drive Belt
Knife Drive Maintenance
Knife Drive Gearing and Belts

Check
Adjust/Replace CAUTION:
1. Turn off power at the C200 controller. 2. Open the cutter head cover. 3. Inspect all knife drive gears for excessive wear, damaged teeth, and presence of excessive oil. Call your Field Service representative if any of these conditions exist. 4. Wipe clean with denatured alcohol on a rag. Use a stiff brush as required for builtup debris. 5. Inspect both knife drive belts for wear or damage to the teeth. Check for grease or oil contamination. To prevent slippage, the belts must be free of any lubricant. 6. Check tension of the upper knife drive belt with the elevator in the up position. Check tension of the lower knife drive belt with the elevator in the down position. The amount of deflection on each belt should be about 6 or 7 mm (1/4 in.).
To prevent premature wear, do not over tighten knife drive belts. If the drive belt makes excessive noise when running, it may be tensioned too tightly.
1. The upper drive belt is tensioned with the elevator in the up position. Loosen the two hex key bolts on the two piece upper tensioning bar. Sliding the drive gear, on the knife assembly side of the cutter head, towards the knife will tighten the drive belt. Sliding it towards the knife motor will loosen the drive belt. 2. If needed, replace the upper belt. 3. Tighten the two adjusting bolts and check the drive belt tension again. Repeat the tensioning procedure, as needed. 4. The lower drive belt is tensioned with the elevator in the up position. Loosen four adjustable mounting bolts on the knife motor mounting bracket. Sliding the knife motor away from the gearing tightens the drive belt. Sliding it towards the gearing loosens the drive belt. 5. If needed, replace the lower belt.
Required Supplies belt, knife drive to idler 28 tooth belt, idler to fly wheel 22 tooth belt, idler to fly wheel 28 tooth
GGT Part No. 180138036 180088001 180138036
6. Tighten the four adjusting bolts and check drive belt tension again. Repeat the tensioning procedure, as needed. 7. If you are through with maintenance: a) Lower and close the front head cover. b) Turn on power at the C200 controller.
Knife Drive Maintenance

5. Repeat steps 2 through 4, setting a high knife speed of 5000 100 rpm. 6. To adjust knife speeds, if needed, qualified personnel can refer to the jumper and potentiometer settings/instructions on GGT technical drawing, part number 078774000.
Knife Drive Motor As part of normal maintenance, you should inspect the motor brushes for the knife drive motor located on the flatway side of the beam. Replace as needed.
Required Supplies brush, 2.3 hp Dumore motor brush cap GGT Part No. 238040201 632500010
WARNING!
Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedule. Knife Speed The knife drive motor is translated to the knife drive train through two drive belts. The actual knife speed should be checked against C200MT parameter settings for knife speed. Verify with a tachometer or strobe light and adjust as needed. Maintenance procedures related to this part of the cutter are covered in the 160 hour maintenance schedule.
Check
High voltages exist inside the vacuum and platform control enclosure, the C200 controller, and the cutting table. There are no operator serviceable parts inside these electrical areas. Only qualified personnel should perform maintenance on these assemblies. Failure to follow these instructions could cause injury or death.
1. Run the C200MT program and open the Parameter Manager. 2. In the Knife and Drill Speed category, set a low knife speed of 1500 100 rpm. 3. Run the Input Output Test (DG 23) diagnostic. See chapter 7. Enable the knife drive motor. 4. Check the knife speed using a tachometer or strobe light.
Drill Bit Maintenance

Drill Bit The drill bit is the part of the drill that cuts holes in the material. Drill bits are available in a variety of sizes and types. See the table on page 171.
CAUTION:
Electric Drill
If your S91 GERBERcutter is equipped with the electric drill option, you will need to perform the maintenance procedures explained in this section. The drill assembly mounts to the subplate at the back of the cutting head. If there are two electric drill units on a cutter, one mounts in front of the other and is referred to as the auxiliary drill. Although one drive motor runs both drills, parameters in the C200MT software allow for independent control of each drill. And, you can run with drill bits of different sizes. Assemblies covered in this section are listed in the table below.
Assembly Drill Bit Drill Assembly See Page 116 118
Drill Motor Cover
When replacing the drill bit, remember to match the drill bit size to the appropriate size collets and ejector rod (for hollow bit drills).
Remove
1. Turn off power at the C200 controller. 2. For hollow bit drills, remove the ejector rod: a) Remove the drill motor cover by removing the two wing nuts. b) Using two wrenches, hold the chuck nut in place while loosening the upper collet. c) Slide the ejector rod up and out. 3. Remove the drill bit: a) Press and hold the detent (shown on next page) while manually turning the drill pulley until the pulley locks in place.
Note:
Air Cylinder Rod
The pulley can be reached from behind the drill motor cover.
Drill Bit
b) Hold down the safety spring. Then depress the detent while loosening the lower collet. c) Remove the drill bit through the presser foot.
Presser Foot
Drill Bit Maintenance

4. For hollow drill bits, install the ejector rod: a) Use the correctsized ejector and slide the ejector rod down through the upper collet.
Drill Bushing
Detent
Set Screw
b) Align the ejector rod so that it is 1.5 to 3 mm (1/16 to 1/8 in.) lower than the bottom of the drill when the drill unit is up. c) Tighten the upper collet finger tight. Using a wrench, tighten 1/4 turn more. d) Tighten the chuck nut 1/4 turn more. 5. Check drill penetration into the bristle: a) Remove air pressure to the drill. Manually, lower the drill to its lower limit. Or, turn power on and use the Input Output Test (DG 23) to lower the drill. b) Mark the drill bit at the point it enters the bristle. Measure the distance from the drill tip to this mark. The measurement should be 6 or 7 mm (1/4 inch).
4. Loosen the set screw that retains the drill bushing. Remove the bushing. 5. If installing a differentsized drill bit, remove the upper and lower collets.
Install
1. If you are installing a differentsized drill bit, install the appropriate collets for the drill bit size and leave them loose. See the table on page 171. 2. Insert the new drill bit. Install the drill bushing and tighten the set screw. 3. The tip of the drill should be inside of the lower bushing when the drill is in the raised position. If not, loosen the two collar clamps, one on each presser foot air cylinder, and raise or lower the presser foot assembly until the drill tip is inside of the bushing. Tighten the collar clamps.
See step 5b.
6. If necessary, adjust by loosening the lower collet and repositioning the drill bit. 7. Install the drill motor cover, if removed.
See step 4b.
8. If you are through with maintenance, Turn on power at the C200 controller.
Drill Assembly Maintenance

Drill Assembly Air Cylinder There are three air cylinder rods for each electric drill unit. Two air cylinder rods raise and lower the drill presser foot. One air cylinder rod raises and lowers the drill unit. These rods must be kept free of dirt and grit so that the drill assembly rides smoothly. Maintenance procedures related to this part of the cutter are covered in the 8 hour maintenance schedule. Drive Belt Check the drive motor belt for wear or damage. To prevent slippage, wipe free of any grease or oil. Replace the belt, if needed. Maintenance procedures related to this part of the cutter are covered in the 160 hour maintenance schedule.
Check Required Supplies belt, standard drill, 1.6 hp belt, GM belt, heavy duty drill, 2.3 hp belt, 1/4 in. dual drill 0.5 hp, inner drill belt, 1/4 in. dual drill 0.5 hp, outer drill belt, 1/4 in. dual drill 2.3 hp, inner drill belt, 1/2 in. dual drill 2.3 hp, outer drill Adjust/Replace CAUTION: GGT Part No. 180138003 180078009 180138003 180138001 180078009 180500020
To prevent premature wear, do not over tighten the drill drive belt(s). If a drive belt makes excessive noise when running, it may be tensioned too tightly.
1. Turn off power at the C200 controller. 2. Remove the drill motor cover. 3. Loosen four adjustable mounting bolts on the drill motor mounting bracket. 4. Replace the belt(s), as needed. 5. Adjust by sliding the drill motor away from the drill to tighten the drive belt. Sliding it toward the drill loosens the drive belt.
1. Turn off power at the C200 controller. 2. Remove the drill motor cover. 3. Inspect the belt for wear or damage to the teeth. Check for grease or oil contamination. To prevent slippage, the belt must be free of any lubricant. Replace, the belt as needed. 4. Check belt tension. The amount of belt deflection midway between the drill motor and pulley should be about 6 or 7 mm (1/4 in.).

6. Tighten the four adjusting bolts and check the drive belt tension again. Repeat the tensioning procedure, as needed. 7. If you are through with maintenance: a) Install the drill motor cover. b) Turn on power at the C200 controller. Drive Motor As part of normal maintenance, you should inspect the motor brushes for the drill drive motor located under the drive motor cover. Replace the brush and cap, as needed.
Required Supplies GGT Part No.
Check
1. Run the C200MT program and open the Parameter Manager. 2. In the Knife and Drill Speed category, set a low drill speed of 1500 100 rpm. 3. Run the Input Output Test (DG 23) diagnostic. See chapter 7. Enable the drill drive. 4. Check the drill speed using a tachometer or strobe light. 5. Repeat steps 2 through 4, setting a high drill speed of 5000 100 rpm. 6. To adjust drill speeds, if necessary, qualified personnel can refer to the jumper and potentiometer settings/instructions on GGT technical drawing, part number 078774000.
brush, 2.3 hp Dumore motor or 1.6 hp Boehm motor brush cap, Dumore motor
238040201
632500010
Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedule. Drill Speed The drill motor runs the heavy duty electric drill(s). The actual drill speed of each drill unit should be checked against C200MT parameter settings for drill speed. Check speeds with a tachometer or strobe light and adjust as needed. Maintenance procedures related to this part of the cutter are covered in the 160 hour maintenance schedule.
WARNING!
High voltages exist inside the vacuum and platform control enclosure, the C200 controller, and the cutting table. There are no operator serviceable parts inside these electrical areas. Only qualified personnel should perform maintenance on these assemblies. Failure to follow these instructions could cause injury or death.
Roundway and Squareway Maintenance

Roundway and Squareway
Beam
The beam transports the cutter head. Electric motors drive the beam along roundways and racks on the cutting table and move the cutter head along the beam. The cutter head travels on the beam along a roundway and a flatway. The combined motions of the beam and cutter head allow the knife to cut complex patterns. Beam assemblies covered in this section are listed in the table below.
Assembly Roundway and Squareway Covers Basic X and Yaxes Advanced X and Yaxes See Page 121 122 122 126
The roundway supports and guides the cutter head as it travels along the beam. It is a round shaft that runs the length of the beam facing toward the takeoff end of the table. The squareway also supports and guides the cutter head as it travels along the beam. This is a flat plate that runs the length of the beam on the takeon end of the table. You must keep the roundway and squareway clean, lightly lubricated, and free of scratches so the cutter head can move freely. Inspect the roundway and squareway for scratches, nicks, and gouges. These defects can damage the roundway or squareway bearings in the cutter head subplate. Call your service representative immediately if you see these conditions. Inspect the beam roundway and squareway for dirt and builtup lint. Clean and lubricate. Maintenance procedures related to this part of the cutter are covered in the 8 hour maintenance schedule.
Squareway Subplate for Cutter Head Squareway Bearings
Wheel Assembly Roundway Roundway Bearings
Yaxis Drive
Second Xaxis Drive
First Xaxis Drive Cam Rollers
Covers Maintenance
Covers The beam control panel cover and end cap Beam cover protect the motors, gearing, and belts that move the beam along the length of the table and move the cutting head across the End Cap Cover beam. These covers must be removed to perform many beam maintenance procedures explained in this section.
Remove
Beam Control Panel Cover
1. Turn off power at the C200 controller. Basic Xaxis and Yaxis
WARNING! To prevent injury, turn off the main circuit breaker for the C200 controller before performing maintenance procedures, unless instructed otherwise.
2. Remove the mounting screws that hold either the beam control panel cover or the end cap cover in place. 3. Slide the cover up over the panel and off the beam.
CAUTION:
Xaxis gearing allows the beam to move along the length of the cutting table. Yaxis gearing allows the head to move on the beam across the width of the cutting table. The first Xaxis gearing is located on the beam under the beam control cover; second Xaxis gearing is located on the beam under the end cap cover.
Do not routinely operate the GERBERcutter without the beam control panel and end cap covers in place; this could cause damage to beam components.
Install
1. Slide the cover over the panel and cables into position on the beam. 2. Install and tighten the mounting screws. 3. If you are through with maintenance, turn power on at the C200 controller.
Basic Xaxis and Yaxis Maintenance

Servo Pinion Gearing and Torque Tube Belts The first and second Xaxis pinion gears should be lubricated regularly and must be adjusted so that there is a slight amount of backlash between the pinion and rack gears.
Note:
Servo Motor Gearing The first and second Xaxis (see below) and Yaxis servo motor gears (see next page) should be lubricated regularly and must be adjusted so that there is a slight amount of backlash between the servo motor gear and the driven gear.
Note:
Check in several places in case there are any high spots in the gears.
Check in several places in case there are any high spots in the gears or racks.
Maintenance procedures related to these parts of the cutter are covered in the 40 hour maintenance schedule.
Adjust
Maintenance procedures related to these parts of the cutter are covered in the 40 hour maintenance schedule.
Adjust/Replace Required Supplies GGT Part No. 180138035

belt, Xaxis
2. Remove the beam control panel and end cap covers. 3. To adjust, loosen the three mounting screws for each servo motor and position the servo motor for a lesser amount of backlash. 4. Tighten the screws and check the amount f backlash again. 5. If you are through with maintenance: a) Install the beam control panel and end cap covers. b) Turn power on at the C200 controller.
1. Turn off power at the C200 controller. 2. Remove the beam control panel and end cap covers. 3. Adjust gearing on each side of the beam: a) Loosen the idler pulley for the torque tube belt so that the belt is loose. b) Disconnect the Xaxis servo motor connector. c) Loosen the servo motor shoulder screw, remove the other two servo motor mounting screws, and swing the servo motor out of the way. d) Turn the Xaxis rack drive gear so that the three holes in the gear line up with the three mounting screws for the rack drive assembly. e) Loosen the three mounting screws for the rack drive assembly and physically adjust the rack drive for a slight amount of backlash. Check this.
First Axis Torque Tube Belt
Rack and Pinion Gears
Xaxis Servo Motor

4. Replace the torque tube belt, if needed.
Adjust
5. Tighten the torque tube belt and tighten the idler pulley screws. 6. Reinstall the servo motor with a slight amount of backlash. Check this. 7. Reconnect the Xaxis servo motor connector. 8. If you are through with maintenance, a) Install the beam control panel and end cap covers. b) Turn power on at the C200 controller.
Countershaft Gear
1. Turn off power at the C200 controller. 2. Remove the beam control panel cover. 3. Adjust the gear: a) Disconnect the Yaxis servo motor connector. b) Loosen the servo motor shoulder screw, remove the other two servo motor mounting screws, and swing the servo motor out of the way. c) Loosen the three mounting screws on the Yaxis countershaft assembly and physically adjust for minimal backlash. d) Tighten the three mounting screws.
Yaxis Servo Gear
4. Check the amount of backlash again. 5. Reinstall the servo motor with a slight amount of backlash. Check this. 6. Reconnect the Yaxis servo motor connector.
Yaxis Countershaft Gear The Yaxis countershaft gear should be lubricated regularly and must be adjusted so that there is a minimal amount of backlash between it and the Yaxis pulley gear.
Note:
7. If you are through with maintenance, a) Install the beam control panel cover. b) Turn power on at the C200 controller.
Check in several places in case there are any high spots in the gears.
Wheel Housing Cam Rollers The wheel housing cam rollers (four on the beam control panel side of the beam) should be lubricated regularly and must be adjusted so that there is no binding against the roundway as the beam travels the full length of the table. Maintenance procedures related to this part of the cutter are in the 40 hour maintenance schedule.
Required Supplies hex wrench, 1/4 in. Adjust GGT Part No. 020945000
Wheel Assemblies Check the four brass wheel assemblies (two on each end of the beam) for wear or damage. Lubricate regularly. Maintenance procedures related to this part of the cutter are covered in the 40 hour maintenance schedule.
1. Turn off power at the C200 controller. 2. Remove the beam control panel cover. 3. Loosen the locking nut on the top of the inside cam roller. 4. Adjust the cam roller until it barely touches the roundway at the tightest spot on the table. 5. Tighten the locking nut. Check again for any binding against the roundway as the beam travels the full length of the table. 6. If you are through with maintenance: a) Install the beam control panel cover. b) Turn power on at the C200 controller.
Cam Rollers
Wheel Assembly
Bite Encoder The bite encoder tracks information about the current bite for use by the C200MT program. It is attached to the takeon side of the beam near the beam control panel (TCW shown).
Bite Indicator Strips Encoder Wheel
Check the encoder wheel for worn areas on the grit surface, wobbling, and correct positioning over the bite indicator strip(s) along the edge of the table surface. Maintenance procedures related to this part of the cutter are covered in the 40 hour maintenance schedule.
Advanced Xaxis and Yaxis Maintenance

Advanced Xaxis and Yaxis
CAUTION:
Squareway Bearings The Yaxis squareway bearings are located on the subplate where the cutter head is mounted. They should be adjusted so that the subplate and cutter head can not be physically moved up and down when force is applied to the back of the subplate, and with no binding on the Yaxis. Maintenance procedures related to this part of the cutter are covered in the 160 hour maintenance schedule.
Adjust
To prevent damage to the cutter and/or fabric, only qualified operators or maintenance personnel who have received GERBERcutter training should perform advanced X and Yaxes procedures.
Roundway Bearings The Yaxis roundway bearings are located on the subplate where the cutter head is mounted. They should be adjusted so that the cutter head and subplate can not be physically twisted on the beam, and with no binding on the Yaxis. Maintenance procedures related to this part of the cutter are covered in the 160 hour maintenance schedule.
Required Supplies hex wrench, 1/4 in. Adjust GGT Part No. 020945000
1. Turn off power at the C200 controller. 2. Loosen the locking nut on the lower bearing. 3. Adjust the eccentric with a screwdriver until the lower bearing barely makes contact with the squareway. 4. Tighten the locking nut.
1. Turn off power at the C200 controller. 2. Carefully tighten the bottom screws for the roundway bearings (two screws for each of four bearings).
CAUTION:
5. Check that: a) The subplate and cutter head can not be moved by lifting from the back. b) There is no binding on the Yaxis. 6. If you are through with maintenance, turn power on at the C200 controller.
To prevent scoring of the roundway, do not over tighten the roundway bearing screws.
3. Check that: a) The subplate and cutter head can not be twisted. b) There is no binding on the Yaxis. 4. If you are through with maintenance, turn power on at the C200 controller.
Roundway Bearings Squareway Bearings

5. Verify that the spring scale does not exceed 6.8 Kg (15 lbs.). If it does: Check for any obstructions, worn bearings, or pulleys. Perform mechanical alignments dealing with the Yaxis covered in this section. 6. If you are through with maintenance, turn power on at the C200 controller.
Test Xaxis
Spring Scale Tests The spring scale tests are used to evaluate the mechanical operation of the X and Yaxes. These tests can determine whether gearing, is set too tightly, lacks lubrication, or is binding due to misalignment or obstructions.
Note:
The spring scale test can not determine if gearing is set too loosely. Use other X and Yaxes alignment procedures in this section to check and adjust for loose gearing.
CAUTION:
1. Turn off power at the C200 controller. 2. Move the cutter head to the farthest -X position on the table and to the center position on the beam. 3. Attach a spring scale to a support bracket on the cutter head. 4. Keep the spring scale held parallel to the Xaxis while pushing the cutter head across the entire length of Xaxis travel. The assistant should use the least amount of force possible applied at a steady rate. 5. Check that the spring scale does not exceed 11.3 Kg (25 lbs.). If it does: Check for any obstructions, worn bearings, or pulleys. Perform mechanical alignments dealing with the Xaxis covered in this section. 6. If you are through with maintenance, turn power on at the C200 controller.
To prevent damage to the cutter and/or fabric, only qualified operators or maintenance personnel who have received GERBERcutter training should perform advanced X and Yaxes procedures.
GGT Part No. 945500034
Required Supplies spring scale Test Yaxis
1. Turn off power at the C200 controller. 2. Move the cutter head to the farthest -Y position on the beam. 3. Attach a spring scale to a support bracket on the cutter head. 4. Keep the spring scale held parallel to the Yaxis while an assistant pulls the cutter head across the entire length of Yaxis travel. The assistant should use the least amount of force possible applied at a steady rate.

7. Tighten the two locking set screws. 8. If you are through with maintenance, a) Install the end cap cover. b) Turn power on at the C200 controller.
Replace Required Supplies belt, Yaxis GGT Part No. 041555006
Yaxis Drive Belt Tension The Yaxis drive belt must be adjusted so that when the servo motors are locked up and the Yaxis is physically pushed or pulled, the belt should not show signs of slack or contact the outer edge of the pulley on the remote side of the cutter when the Yaxis is slewed from one end of the beam to the other.
CAUTION:
To prevent damage to the cutter and/or fabric, only qualified operators or maintenance personnel who have received GERBERcutter training should perform the advanced X and Yaxes procedures.
1. Turn off power at the C200 controller. 2. Remove the beam control panel and end cap covers. 3. On the remote side, loosen the two locking set screws on the sides of the adjusting screws for the Yaxis belt pulley. 4. Remove the four screws that attach the Yaxis belt to the subplate to which the cutter head is mounted (indicated).
Adjust
1. Turn off power at the C200 controller. 2. Remove the end cap cover. 3. Loosen the two locking set screws on the sides of the adjusting screws for the Yaxis belt pulley.
Adjusting Screw
Locking Set Screw
5. Remove the belt from the adjustment pulley and from the track that runs under the beam. 6. Install the new belt. 7. Follow steps 4 through 7 of the procedure for adjusting the belt. 8. If you are through with maintenance: a) Install the beam control panel and end cap covers. b) Turn power on at the C200 controller.
4. Adjust the screws in to tighten the belt or out to loosen the belt. 5. Slew the head back and forth to check the belt skew. Repeat step 4 as needed. With the cutter head slewed toward the remote side, you should be able to insert several fingers under the belt at a location 60 cm (2 ft.) from the end cap cover and raise it 2.5 to 3.8 cm (1 to 1.5 in.).

Squaring the Beam In order to correctly cut pieces from a marker the beam must be square to the table. Maintenance procedures related to this part of the cutter are covered in the 160 hour maintenance schedule.
CAUTION: Adjust
1. Position the cutter head at the first Xaxis side of the beam (nearest to the beam control panel). 2. Press the EStop button on the beam control panel to disable servos. 3. Position two Cclamps on the table rack, one on each side of the beam. 4. Turn power off at the C200 controller. 5. Remove the end cap cover. Use a pencil to scribe a mark for the current beam position onto the roundway or rack. 6. Loosen the collar clamp on the torque tube pulley. 7. Refer to step 2b of the Check procedure and physically move the second Xaxis side of the beam relative to the pencil mark: If the second Xaxis side of the beam leads, then move the beam in the -X direction an amount equal to the recorded measurement. If the first Xaxis side of the beam leads, then move the beam in the +X direction an amount equal to the recorded measurement. 8. Tighten the coupling clamp on the torque tube pulley. 9. Enable servos and then run the Beam Square Test diagnostic again to check the adjustment. 10. If you are through with maintenance, a) Install the end cap cover. b) Turn on power at the C200 controller.
To prevent damage to the cutter and/or fabric, only qualified operators or maintenance personnel who have received GERBERcutter training should perform the advanced X and Yaxes procedures.
Check
1. Run the Beam Square Test diagnostic to make four cuts, one at each corner of an imaginary square. See chapter 7. 2. The difference in the two measurements taken diagonally across the imaginary square determines: a) Whether the beam is square. b) If it is not square, whether the first X or second Xaxis leads and by how much. Record this value for use in step 5 of the adjust procedure. 3. If the beam is not square within 1 mm (1/32 in.), adjust (square) the beam.
Work Surface Maintenance
Table
The cutting table provides a work surface for cutting material. Major assemblies of the table include the beam, bristle work surface, filtration, vacuum generator, and material handling. TCW systems also have assemblies related to the traveling platform. Table assemblies covered in this section are listed in the table below.
Assembly Work Surface Work Surface Cleaner Roundways and Racks Filters Vacuum Assembly Material Handling Systems Platform See Page 130 132 133 134 135 138 141 Inspect
Work Surface The BRISTLE SQUARES form the work surface of the cutter. They are small, plastic squares with bristles on one side and a perforated base on the other. The BRISTLE SQUARES fit into aluminum slats on TCW and ZVC systems and in plastic grids on Static systems. BRISTLE SQUARES last longer if you clean them regularly and move them to different positions on the table to spread wear more evenly.
1. If your system is a TCW or ZVC do the following: a) Turn power on at the table control panel. b) To access all portions of the work surface, set the Conveyor Mode to Manual. c) Jog the conveyor to move unexposed portions of the bristle work surface into view. 2. Inspect the BRISTLE SQUARES for lint, broken bristles, and other cutting debris. Clean them if necessary. 3. Inspect the BRISTLE SQUARES for uneven wear, scarring, or creasing. Rearrange the BRISTLE SQUARES if necessary. Sometimes the squares may be damaged beyond repair; this could be a sign of another problem. If you see such damage, call your Field Service representative.
Work Surface Maintenance

c) Remove the grid. You can remove the remaining grids by hand. d) Position the grid on a portion of the cutting table that is less worn.
Install
Clean
1. Vacuum the BRISTLE SQUARES to remove debris. 2. For TCW or ZVC systems, jog the conveyor to reach unexposed portions of the bristle work surface.
Remove/Rearrange
Install the BRISTLE SQUARES in the work surface of TCW and ZVC systems by snapping them into place in the slats. Install the BRISTLE SQUARES in the work surface of Static systems: a) Replace all but the last BRISTLE SQUARE grid in the table. b) Place the bristle locating over the edges of the bristle surrounding the remaining grid.
To rearrange BRISTLE SQUARES for TCW or ZVC systems: a) Working on one slat at a time, set a clamping pliers deeply into the bristle and pull the square out of the slat. See below. b) Remove the other squares in this slat by hand.
Locating Guides
c) Move the square to a part of the slat that is less worn. d) Jog the conveyor to reach unexposed portions of the bristle work surface. To rearrange BRISTLE SQUARES for Static systems: a) Locate the first grid that you want to remove. b) Set one clamping pliers deeply into one side of the grid. Set another clamping pliers deeply into the bristle on the opposite side of the grid.
c) Snap the remaining grid into place and remove the bristle locating guides.
Required Supplies bristle locating guides bristle locating guides
GGT Part No. 023678000 023679000
Work Surface Cleaner Maintenance

Work Surface Cleaner TCW systems have a mechanical work surface cleaner. This is an auger located on the takeoff end of the table. The auger rotates through the bristle work surface that is not exposed. The lint and debris that falls from the auger collects in a basin at the take off end of the system. You must clean this basin periodically.
Inspect
Gear Box The gear box for the work surface cleaner is located on the remote side of the cutter at the takeoff end of the table. Periodically, check the fluid level in this gear box. The third time you check the fluid level, drain and replace with SAE 600 weight oil. Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedule.
1. Turn off power at the C200 controller. 2. Open the access doors at the takeoff end of the TCW table. 3. Check the basin for accumulated lint and cutting debris. Clean the basin, if necessary.
Gear Box Cover
WARNING!
Avoid breathing in lint collected in the basin of the work surface cleaner. Wear a mask suitable for cleaning lint.
Access Doors
Pillow Block Bearings There are two pillow block bearings located inside of the work surface cleaner basin, one on each side of the cutter. Open the access doors to lubricate these bearings. Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedule.
Clean
1. Vacuum out the lint and debris that has collected in the basin. 2. Inspect the auger for damage of any kind. If you notice any cracks, heavy scoring, or other signs of damage, call Field Service immediately. 3. If you are through with maintenance, turn power on at the C200 controller.
Roundways and Racks Maintenance

Roundways and Racks The beam travels the length of the cutting table on roundways and racks. The beam can not travel smoothly if the roundways and racks are excessively dirty or damaged.
Racks The racks are toothed tracks that run the length of the cutting table. Motors and gears in the beam drive the beam along the racks. The beam can not travel smoothly if the teeth of the racks are damaged or dirty.
Inspect
Roundway
1. Turn off power at the C200 controller. 2. Check the racks for damaged teeth, scoring, or abrasions. If you see any of these conditions, call your Field Service representative. 3. Inspect the racks for builtup dirt and lint.
CAUTION:
Use care not to damage the teeth of the rack. Clean only when absolutely needed.
Rack
Roundways The roundways run the length of the cutting table. Motors for the beam drive the beam along the roundways. The beam can not travel smoothly if the roundways are damaged or dirty. Inspect the roundways for abrasions and scoring. Contact your Field Service representative if you notice any. Inspect the roundways for builtup dirt and lint. Clean, as needed. Maintenance procedures related to this part of the cutter are covered in the 8 hour maintenance schedule.
Filters Maintenance
Filters The GERBERcutter uses filters as part of the vacuum system to trap lint and moisture from the work environment. Vacuum Filter The vacuum filter canister for S91 systems is a drum with a filter inside. The vacuum filter traps lint and other debris from the table top. Keep the filter clean to prevent a decrease in vacuum.
Note: WARNING! Avoid breathing in lint from the filters. Wear a mask suitable for cleaning the filter.
CAUTION:
Do not use compressed air to blow out the drum as cutting debris may work its way into the turbine or blower and cause damage.
The onscreen gauge in the C200MT program will alert you to decreased vacuum pressure.
Maintenance procedures related to this part of the cutter are covered in the 8 hour maintenance schedule. Stack Filter The stack filter is located in a canister on the exhaust stack. For TCW systems, the stack is part of the mast at the takeon end of the table. For Static and ZVC systems, the stack is located at the external vacuum assembly. The stack filter traps debris which might damage the vacuum generator. You must keep this filter clean to ensure the proper working of the vacuum generator. Maintenance procedures related to this part of the cutter are covered in the 160 hour maintenance schedule.
For a TCW system the drum is located at the takeon end of the table under the front ramp. For ZVC and Static systems, the drum is mounted inline between the external vacuum assembly and the cutting table.
Filter
Cover
Required Supplies filter element, stack
Required Supplies filter element, Static or ZVC filter element, TCW
GGT Part No. 022810000 460500102 WARNING! Avoid breathing in lint from the filters. Wear a mask suitable for cleaning the filter.
Vacuum Assembly Maintenance
Air/Reducer Filter On TCW systems, there are one or more air/reducer filters located on the exhaust stack and mast of the table. These filters improve air flow. If they get clogged, air pressure drops.
CAUTION:
Cover The vacuum generator assembly for TCW systems is located under the front ramp or (takeon cover). This ramp must be removed to perform maintenance procedures such as lubrication and tensioning of the belt(s). External vacuum assemblies for Static and ZVC systems have either a jack shaft cover or a coupling guard that must be removed to perform maintenance procedures.
Remove
Before opening the drain valve, reduce air pressure manually by turning the cap. Dirty liquid may spray and stain material.
Cap
1. Turn off power at the C200 controller. For Static and ZVC systems, also turn off power at the external vacuum assembly and at the table control (or lay puller control) panel.
Drain Valve
2. Depending on your system: For TCW systems, remove mounting screws and shims at both sides of the front ramp. With the help of an assistant, lift off the cover. For Static or ZVC systems with a Hoffman blower and coupling guard, remove four screws from the coupling guard. Lift off the coupling guard. For Static or ZVC systems with a Spencer turbine, unlatch three fasteners on the jack shaft cover. Lower the cover and move aside.
Install
Vacuum Assembly The vacuum generator assembly includes the vacuum generator and the vacuum generator motor. The motor drives the turbine generator. In all TCW systems and some ZVC and Static systems, the motor drives a turbine or blower by use of a single wide or multiple narrow drive belt(s). In most ZVC and Static systems, a coupling connects the motor and a blower.
1. Depending on your system: For TCW systems, with the help of an assistant, lift the cover into place. Reposition the shims. Install and tighten the mounting screws.

For Static or ZVC systems with a Hoffman blower and coupling guard, reposition the coupling guard. Install and tighten four screws for the coupling guard. For Static or ZVC systems with a Spencer turbine, reposition the jack shaft cover. Latch the three fasteners. 2. If you are through with maintenance:
Adjust/Replace
Drive Belt Tensioning Drive belt(s) between the motor and generator can stretch, fray, or wear. Adjust belt tension or replace as needed. Maintenance procedures related to this part of the cutter are covered in the 160 hour maintenance schedules.
a) Turn power on at the external vacuum assembly, if applicable. b) Turn power on at the C200 controller. Motor and Generator Lubricate the motor and generator regularly. Check belt tension or coupling alignment between the motor and generator. Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedules. For systems with a Spencer turbine or an Hoffman blower with pillow block assembly, you need to check belt tension regularly and adjust belt tension as needed. For systems with a Hoffman blower coupled to the motor, you need to check coupling alignment.
CAUTION:
Required Supplies belt, 50 Hz (4 per unit) belt, 50 Hz (5 per unit) belt, 60 Hz (5 per unit)
GGT Part No. 180078008 180500038 180500006
1. Turn off power at the C200 controller. For Static and ZVC systems, also turn off power at the external vacuum assembly and at the table control (or lay puller control) panel. 2. As required, remove the front ramp or jack shaft cover to access the drive belt(s). 3. Adjust or replace as follows: a) Loosen the nuts on four bolts that secure the generator motor. b) If replacing a belt, remove all belt(s). Install new belt(s).
Note:
All belts must be replaced, even if only one is worn or frayed.
c) With the help of an assistant, reposition the motor and then tighten the nuts. d) Check belt tension again and compare the deflection to the manufacturers specs.

4. If required, replace the front ramp or the jack shaft cover. 5. If you are through with maintenance, a) Turn power on at the external vacuum assembly. b) Turn power on at the C200 controller. 2. Remove the coupling cover. Coupling Alignment For motors coupled to an Hoffman blower, the coupling between the motor and Hoffman blower must be checked for alignment regularly. It is possible to check coupling alignment when the assembly is cold. However, the hot alignment method, which checks after the unit has run for at least an hour, is more accurate. Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedules.
CAUTION:
Align (cold system method)
1. Make sure the C200 controller is turned off. For Static and ZVC systems, also make sure the power is off at the external vacuum assembly and at the table control (or lay puller control) panel.
3. Adjust alignment as follows: a) Loosen the nuts on four bolts that secure the generator motor. b) Place a straight edge across the hub and verify with a feeler gauge that the centerline for the shaft of the motor is higher than the centerline for the shaft of the blower by the specified amount. The spec for the cold system method is printed on a plate affixed to the blower. c) Use shims as required. Then tighten the four bolts. 4. If you are through with maintenance, a) Turn power on at the external vacuum assembly. b) Turn power on at the C200 controller.
Align (hot system method)
From Cutter
Motor
Coupling Guard
Blower
1. Run the vacuum system for an hour or more. 2. Turn off power at the C200 controller. For Static and ZVC systems, also turn off power at the external vacuum assembly and at the table control (or lay puller control) panel. 3. Remove the coupling cover.
Material Handling Systems Maintenance

Material Handling Systems Material handling systems depend on the type of cutter. These may include: the clamp bar, resealer, conveyor, or motorized lay puller. Clamp Bar On TCW systems, the clamp bar works with the conveyor to pull material onto the cutting table. The air cylinders that raise and lower the clamp bar require cleaning and lubrication to work smoothly. Maintenance procedures related to this part of the cutter are covered in the 40 hour maintenance schedules. Resealer If your cutter has the resealer option shown below, routine maintenance procedures include lubricating the air cylinder rods and checking that the bar moves up and down evenly.
4. Adjust alignment as follows: a) Loosen the nuts on four bolts that secure the generator motor. b) Place a straight edge across the hub. The straight edge should lay flat. c) As shown above, measure the distance between the outside hubs at four places, each 90 degrees from the previous location. If the distance between the four measurements is not within 0.40 mm (1/64 in.), then go to step 5. 5. When the system is cold, use shims to raise or lower the motor, as required. (See the cold system method.) 6. Tighten the four bolts. 7. If you are through with maintenance, a) Turn power on at the external vacuum assembly. b) Turn power on at the C200 controller.
Resealer Bar
Maintenance procedures related to this part of the cutter are covered in the 40 hour maintenance schedules.
Conveyor Drive Gear Box The gear box for the conveyor drive is located at the takeon end of the cutter. Periodically, check the fluid level in this gear box. The third time you check the fluid level, drain and replace with SAE 600 weight oil. Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedule. Conveyor Drive TCW and ZVC systems use a conveyor to move material on and off the cutting table. Potentiometers for the drive motor that jogs the conveyor can be aligned to accommodate a variety of spreads. 3. Jog the conveyor to start moving the spread onto the table. 4. Adjust the potentiometers for the Baldor drive as follows: a) Set an initial torque, T1, for ramp up speed. b) Set a normal operation speed, T2 (Range for torque is 0 to 100%). c) Set the time for ramp up, A, from 0 to T1 and from T1 to T2. (Range for A is 0 to 7 sec.) These settings should result in the shortest and smoothest acceleration capable of pulling a production spread onto the cutting table.
WARNING!
High voltages exist inside the C200 controller, vacuum and platform electrical enclosure and the cutting table. There are no operator serviceable parts inside. Only qualified personnel should perform maintenance on these assemblies. Contact your Service Technician in case of a problem. Failure to follow these instructions could cause injury or death.
Align Note:
Refer to the documentation that came with the drive motor.
1. At the platform control panel, set the Conveyor Mode to Manual. 2. For ZVC systems, remove the takeon end cover. For TCW systems, open the door to the vacuum and platform electronics (shown below).
5. Position a typical spread on the spreading table. Check the alignment by jogging the conveyor; repeat step 4 as required.

Lay Puller Gear Box The gear box for the lay puller drive is located under the cutting table. Periodically, check the fluid level in this gear box and replace with SAE 600 weight oil. Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedule. Lay Puller Drive Static systems use a motorized lay puller to move a spread onto the takeon end and along the length of the cutting table. Potentiometers for the drive motor that jogs the lay puller can be aligned to accommodate a variety of spreads.
Align Note:
Do not refer to the documentation for the drive motor when setting potentiometers. Use the following procedure instead.
1. Initial settings for the Reuland drive are: Turn the torque potentiometer (pot) fully counter clockwise. Turn the time pot fully clockwise. 2. Jog the lay puller to start moving the spread onto the table. Adjust the torque pot clockwise until the lay puller bar just begins to move. 3. Again, jog the lay puller and readjust the torque pot so the maximum delay before the bar begins to pull is 1 or 2 seconds. 4. Position a typical spread in the lay puller. Repeat steps 2 and 3. 5. Adjust the time pot counter clockwise (decreasing) to attain the shortest and smoothest acceleration acceptable for pulling a production spread onto the cutting table.
WARNING!
High voltages exist inside the C200 controller, vacuum and platform electrical enclosure and the cutting table. There are no operator serviceable parts inside. Only qualified personnel should perform maintenance on these assemblies. Contact your GGT Service Technician in case of a problem. Failure to follow these instructions could cause injury or death.
Platform Maintenance
Platform S91 TCW systems travel on rails between spreading tables. Power is transferred through an overhead cable trolley. Platform drive maintenance includes: Lubricating the platform drive chain, sprocket bearings, and cam roller bearings. Checking fluid levels in the platform drive gear boxes on two wheel assemblies. Lubricating platform wheel cam roller bearings and shaft bearings on four wheel assemblies.
Overhead cable trolley maintenance includes cleaning and lubricating the roller bearings. Maintenance procedures related to this part of the cutter are covered in the 960 hour maintenance schedule.
Overhead Cable Trolley
Platform Drive Wheel Assembly Wheel Assembly
Platform Maintenance
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The C200MT cutter control software provides the following features to assist you in troubleshooting your GERBERcutter. Error messages. Diagnostics.
These features are explained briefly in this chapter. For more information, refer to the C200MT Software Users Guide. Additional troubleshooting tools available currently or in the near future include: Training (CBT) on CDROM. Service Parts on CDROM. Applications manual.
See sections later in this chapter. Contact GGT Product Support or your local Field Service office for information on availability and how to obtain copies. Product Support If a condition still exists after troubleshooting, call your GGT Product Support or local Field Service office for help. Within the United States and Canada, call 800-999-1448. Otherwise, call you local Field Service office. Have your service contract number ready.
Chapter 7 Troubleshooting Page 143
Error Messages
The GERBERcutter displays an error message dialog box when it detects an error condition. The system numbers these error messages for easy reference. The first digit of the error number defines the error class. The error classes range from 1 to 4, with class 1 being the least severe. PreProcessor error messages do not have an error number.
Error Message Type Class 1 FEP Class 1 MCC Class 2 Class 3 Class 4 Error Number Range 1000-1999 1000-1999 2000-2999 3000-3999 4600
This section gives a brief overview of the types of error messages, samples of messages, and recommended solutions. A complete list of errors and solutions is included in the C200MT Software Users Guide.
Page 144 Chapter 7 Troubleshooting
Class 1 FEP Errors Class 1 FEP (workstation PC) errors relate to conditions with the cut file. When a class 1 error occurs, the system stops cutting. To resume cutting, see the recovery procedures in chapter 3. The following table gives some keywords you might find in this type of error message, actual samples of class 1 FEP error messages, and possible solutions. Simple solutions, such as editing cut data or restarting the program, should be tried before contacting Field Service.
Note:
Before trying solutions that involve reloading software, refer to the C200MT Software Users Guide for a complete listing of messages or call Field Service.
Possible Solutions Edit or regenerate cut data file. Change parameter settings. Reposition the spread. Quit the C200MT program, turn off the power, and restart. Call Field Service if condition persists. Sample Messages 1002 Illegal character in logical block 1429 SBITE: Cant bite without reorder 1105 Wrong number of parameters: TR 1302 Overrun on serial 2 line
Message Keywords illegal; invalid; not found; max allowed; converting file; character; code; data; point; block; stops; SBITE wrong number; too many; out of range; overrun; not responding; failed parameter; queue; serial line; buffers; PC controller \SYSFILES\xxx.INT offtable
Move the origin. Check the cut file format. Check that the cutter head and beam are not too close to the limit switches. Quit the C200MT program and reload the C200MT software. Call Field Service if condition persists.
1017 Offtable -X
timeout; not found \SYSFILES\ENGLISH\ xxx.INT
1410 Timeout Error requesting input status 1418 \SYSFILES\ ENGLISH\ DG23.INT not found
Class 1 MCC Errors Class 1 MCC errors relate to conditions with the commands that the Motion Control Computer (MCC) sends to the cutting table. When a class 1 MCC error occurs, the system stops cutting. To resume cutting, see the recovery procedures in chapter 3. The following table gives some keywords you might find in this type of error message, actual samples of class 1 MCC error messages, and possible solutions. Refer to the C200MT Software Users Guide for a complete listing of messages.
Message Keywords initialization not completed limit switch; knife motor; beam control panel Possible Solutions Check cable connections, loose wiring, and fuses. Check air pressure. Check limit switches. Change parameters. Initialize the cutter. Turn knife motor on. Slew beam. up; down; position; not on tool; bite sensor; knife; drill; auxiliary drill; sharpener solenoid failed; rejected; invalid; logging; aborted; not oriented number; memory block; coefficients; data; encoder; Caxis Use Input Output Test (DG23) diagnostic to check for signal. Examples 1006 Error occurred while homing (initializing) 1008 Caxis could not get off limit switch 1423 Y limit switch active
1021 Bite Sensor not down 1107 Drill not up
Quit the C200MT program, turn off the power, and restart. Call Field Service if condition persists.
1009 Encoder reset failure 1315 Bad piece number 1619 Error setting X Dynamic coefficients
Class 2 Errors Class 2 errors relate to conditions resulting from communication and data processing. When a class 2 error occurs, the system displays an error message. To resume cutting, see the recovery procedures in chapter 3. The following table gives some keywords you might find in this type of error message, actual samples of class 2 error messages, and possible solutions. Refer to the C200MT Software Users Guide for a complete listing of messages.
Message Keywords following error; level too high bite; conveyor; vacuum Possible Solutions Quit the C200MT program. Check sensor or mechanical condition of the system. Call Field Service if condition persists. Quit the C200MT program, turn off the power, and restart. Call Field Service if condition persists. Use the KI Calibration (DG20) diagnostic to calibrate the KI sensor. Call Field Service if condition persists. Edit cut file. Change parameter. Examples 2000 X following error 2552 Vacuum level too high to bite (ZVC)
overflow; invalid; too many; no more; bad vacuum; parameter; BGL ASCII failure KI
2330 Non-numeric char in ASCII to integer conversion 2357 Bad parameter table 2006 KI sensor failure
knife down
2350 Knife down move length exceeds max
Class 3 Errors A class 3 error is a serious hardware error. Cutting halts. To resume cutting, see the recovery procedures in chapter 3. The following table gives some keywords you might find in this type of error message, actual samples of class 3 error messages, and possible solutions. Refer to the C200MT Software Users Guide for a complete listing of messages.
Message Keywords offscale Possible Solutions Check data format and regenerate cut file. Set origin closer to the initialization point of the table. Check cabling to BCC. Check power to the servo drive. Fix the EStop condition. Press the Servo Power button. following error; invalid; unknown; excessive conveyor; knife Quit the C200MT program. Check mechanical condition of the system. Call Field Service if condition persists. Quit the C200MT program, turn off the power, and restart. Call Field Service if condition persists. 3000 X max following error 3810 Excessive Knife Current Examples 3400 Offscale +X
unknown; failed BCC; beam control panel; servo; emergency stop
3010 Unknown BCC error detected by 68K 3237 C servo drive failed
invalid; error sending sharpen; servo
Class 4 Errors A class 4 error is a serious nonrecoverable C200 controller error caused by either a hardware or software condition. Power down the system, then power up again. If the error appears again, call Field Service. To resume cutting, see the recovery procedures in chapter 3.
Diagnostics
Diagnostics included in the C200MT program provide tools which can be used by the person in your company responsible for GERBERcutter maintenance or by Field Service to ensure cutter performance. Diagnostics used for routine maintenance and covered in this section include: Input Output Test (DG23). KI Calibration (DG 20). C Home to System Zero. Heel to Heel Cut Test. Beam Square Cut Test. Knife Offset Setup Cut Test. For detailed information about diagnostics that are not covered in this section, refer to the C200MT Software Users Guide.
Note:
Diagnostic
Use To
Input Output Test (DG 23) Servo I/O Test (DG 16)
Check MCC input and output signals. Read and zero selected encoders; control output voltage of digitaltoanalog converters; display input voltage for analog todigital converters. Set Knife Intelligence deflection voltage. Rotate the Caxis to any angle. Run in single step mode to check cut file data. Run one cut file continuously in the same place. Display the difference (error) between how much the conveyor and the beam move during a bite. Calculate change in distance from current position to origin. Calibrate conveyor and CTOT speeds. Adjust this knife setting and command the knife to plunge four times in a straight line. Calculate new stepsize settings for the X and Yaxes. Test, setup, or troubleshoot hardware for the vacuum zone control.
KI Calibration (DG 20) C Axis Angle Single Step Continuous Run Display Bite Adjust Values Position Info Conveyor/CTOT Speed Calibrate C Home to System Stepsize Setup Zone Vacuum Exerciser
Diagnostic Cut Tests
Use To
Multiple Horizontal Lines Multiple Vertical Lines Multiple 45 Degree Lines 50" Square Test Concentric Circles Beam Square Test Heel to Heel Test Yaw in X Test Yaw in Y Test 10" Square Geometric Shapes 5' Bite Test Knife Offset Setup Drill 1 Offset Setup Drill 2 Offset Setup Pen Offset Setup
Check Caxis mechanical alignment Check Caxis mechanical alignment. Check X, Y, and Caxes electrical alignments. Square the beam. Test cutting. Square the beam. Check knife mechanical alignment. Check Caxis mechanical alignment in Xaxis. Check Caxis mechanical alignment in Yaxis. Center drill hole. Check drill placement. Test cutting. Test a conveyorized GERBERcutter. Check knife alignment. Check main drill alignment. Check auxiliary drill alignment. Check pen alignment.
Software Diagnostics (Used for software development only) Path Intelligence
Calibration Watch Forces
Calibrate PI. Check XY forces on the knife blade.
Selecting Diagnostics Choose the commands in the Diagnostics menu to access diagnostics. Additional diagnostics are available in the Cut Tests, Software Diagnostics, and Path Intelligence submenus.
Input Output Test (DG 23) This diagnostic can be used to test individual motors, switches, lights, and other components. Only use this diagnostic when told to by this manual or by Field Service.
To run diagnostic
1. Turn on the GERBERcutter and run the C200MT program. 2. Optional Enable servo power and then initialize the cutter. 3. From the Diagnostics menu, click Input Output Test (DG 23). The system displays a test screen. On this screen, active shows as green; inactive shows as red.
WARNING!
Stand away from moving parts on your GERBERcutter when using this diagnostic. Injury or death may result if you are in the path of GERBERcutter parts when they move. Depending on which control you are testing, part of the GERBERcutter may move. This can be, but is not limited to, the knife blade, drill, conveyor, and other mechanical parts.
4. To test an output signal, use the arrow keys or pointing device to highlight the signal that you want to test. Then hold down the Ctrl key and press the Space bar. 5. To test an input signal, you will need to use a cutter component. For example, press a button. The listed signal changes either from 0 to 1 or 1 to 0. The actual component on the cutter you are testing becomes active or inactive.
Note:
On this screen, active shows as green; inactive shows as red.
6. After you finish testing components, press Esc or click the Exit I/O Diagnostic button. KI Calibration (DG 20) Use this diagnostic at the beginning of each shift to calibrate the Knife Intelligence deflection voltage sensor (if the cutter can utilize KI).
Note:
To check if calibration is required, first use the Null KI command (see chapter 5).
Required Supplies right angle handle hex key set
To run diagnostic
1. Turn on the GERBERcutter and run the C200MT program. 2. On the presser foot bowl assembly, loosen the clamping screw that locks the transducer adjusting screw. See chapter 6.
Note:
For this diagnostic, it is not necessary to remove the presser foot bowl assembly (as shown below for clarity purposes only).
Clamping Screw
3. Enable servo power. 4. From the Diagnostics menu, select KI Calibration (DG 20). 5. Adjust the transducer screw until the output voltage is at, or near, zero (0). 6. Tighten the clamping screw to lock the transducer adjusting screw. 7. When finished, press Esc or click the Exit DG20 button. 8. Use the Null KI command to null Knife Intelligence (see chapter 5).
C Home to System Zero Diagnostic The C Home to System Zero diagnostic allows you to adjust knife yaw and command the system to plunge the knife four times in a straight line.
To use C Home to System Zero
1. Turn on the GERBERcutter and run the C200MT program. 2. Open Parameter Manager and use the Advanced button to enter a password and change access level to Supervisor or Field Service. Refer to the C200MT Software Users Guide. 3. Place a large square of paper on the cutting surface. Position the cutter head over the paper. 4. From the Diagnostics menu, select C Home to System Zero. 5. In the dialog box, type the number of degrees to adjust the knife setting. 6. Press the Plunge Knife 4 Times button. 7. After the knife has plunged four times, compare the cuts to the example shown below and in the dialog box. Make any necessary adjustments.
8. Reposition the head over the paper. Repeat steps 4 through 7 until satisfied with results. 9. Initialize the cutter to make your changes effective. 10. When finished, press Enter or click the OK button. 11. When prompted, you can choose to save changes to all setups. 12. If you clicked Yes in step 11, the system prompts how many setups were changed. Press Enter or click the OK button.
Running Cut Tests A Cut Test is actually just a marker designed to check a specific cutter operation. Run Cut Tests as you would any marker, replacing the spread with a piece of paper. Specific steps required for a Cut Test diagnostic and the expected results are explained in each topic.
To run Cut Tests
1. Run the C200MT program. 2. Enable servo power. 3. Initialize the cutter. 4. Position paper and plastic on the table. See each diagnostic for the specific paper size to use. 5. Turn on the vacuum. 6. Slew the cutter head to the lower left corner of the paper. 7. On the beam control panel do all of the following: Press the ORIG button. Set CUTTING SPEED to 10, unless otherwise noted. Set KNIFE to ON. 8. From the Diagnostics menu, choose Cut Tests. Then select the appropriate diagnostic. 9. Press the Start button to run the diagnostic. The GERBERcutter displays the status screen while the diagnostic is running. 10. When processing is complete, at the beam control panel do all of the following: Set KNIFE to OFF. Press the VAC ON/OFF button. 11. Slew the cutter head out of the way, unless otherwise noted. 12. Check the results as explained in the topic for each diagnostic.
Beam Square Test Use this Cut Tests diagnostic to check that the beam is square with the cutting table. In this diagnostic, the cutter plunges the knife at each corner of a square. If the measurements from corner to corner are the same, neither end leads as the beam travels along the table and the beam is square. If the one end leads, perform the maintenance procedure on page 129.
To run the diagnostic
1. Run the Cut Tests diagnostic as (see page 155) except: a) Place a piece of paper at least 1.5 m (60 in.) square and preferably larger on the table. This diagnostic must be rerun after making any adjustments. b) Before initializing the cutter, turn Run Time Biting OFF. 2. To check results, first measure a diagonal line from top right tip to bottom left tip of the knife plunges. Then repeat from top left tip to lower right tip to get the second measurement. Each line should be 160 cm (63 in.).
First Measurement
Second Measurement
3. Compare the measurements with those in the following table.

Measurement Indication Action
Equal to within 1.0 mm (0.03 in.) First is greater than second
The beam is square. The beam is not square. The +Y end of the beam leads the -Y end.
None Use the difference between these measurements to adjust beam alignment. See page 129. Same as above.
Second is greater than first
The beam is not square. The -Y end of the beam leads the +Y end.
Heel to Heel Test Use this Cut Tests diagnostic to check the mechanical alignment of the knife in the Caxis. The knife must be properly aligned for accurate cutting. In this diagnostic, the system plunges the knife twice so that alignment can be checked.
1. Run the Cut Tests diagnostic as normal (see page 155) except: a) Place a piece of paper 0.5 m (20 in.) square or larger on the table. b) After initializing the cutter set Knife speed to 2,500 rpm for all S91 systems.
CAUTION:
Knife speed must be set as indicated above to simulate the knife load caused by cutting a spread and to ensure that results of this diagnostic are accurate.
c) Set Cutting speed to 1. 2. To check results, compare your test knife cuts with the drawing shown below.
Measurement
(a)
(b)
Good
Unacceptable
a) If results are good, go to step 3. b) If the knife alignment is unacceptable, your trained GERBERcutter maintenance person can adjust knife alignment using the procedure on page 111. Otherwise, call Field Service.
Note:
A slight negative offset is beneficial under certain cutting applications. Contact Field Service for recommendations and limitations.
3. When alignment is correct, measure the heeltoheel distance. If this measurement falls outside the 2.7 to 14.3 mm (0.5 to 0.56 in.) range, your trained GERBERcutter maintenance person can adjust knife alignment using the procedure on page 111. Or, call Field Service.
Knife Offset Setup

Use this Cut Tests diagnostic to check that the cutter is using the correct value for knife offset. Knife offset is the location of the knife blade relative to the origin light. If the system is using the wrong value for knife offset, cuts will not be made in the correct location.
Note:
This diagnostic should be used whenever the laser light or head is changed.
1. Run the Cut Tests diagnostic as normal (see page 155) except place a piece of paper 1.5 m (60 in.) square or larger on the table. The cutter positions the knife at, or near, the origin and executes a knife down cycle. 2. After cutting stops, the Systems Message box prompts that processing is complete. Use the Move to Origin command. 3. To check results, make sure that the origin light shines exactly on the intersection of the horizontal and vertical lines. If it does not, do one of the following: Continue with steps 4 through 6. Call Field Service. 4. Use the Position Info diagnostic (refer to the C200MT Software Users Guide) to determine the exact location. 5. Make appropriate changes to the Offset in X - Knife and Offset in Y- Knife parameters in the System Setup category. 6. Reorigin and repeat this diagnostic to check your changes.
Training (CBT)
GERBERcutter computer based training (CBT) is designed to work right on your cutter. More than just training, the GERBERcutter Training CD includes: Basic operation modules. Maintenance modules. Application wizards. Navigator.
Video and animation, along with text, guides you stepbystep through basic operations and complex maintenance procedures. Application wizards offer suggestions to resolve conditions such as pushing or fusing. The Navigator shows you at a glance the types of information available and jumps right to the specific information you need. Ask your local Sales office about availability.
To run Training (CBT) at your cutter
1. Insert the CDROM in the disc drive. 2. From the Help menu, select Training (CBT). The Training software must be installed on your cutter in order to access this program. Refer to installation information in the CDROM insert.
Service Parts
The GGT Service Parts documentation on CDROM provides the latest parts information for your GERBERcutter. Assembly drawings in exploded view are provided with indexes that identify names and part numbers. Drawings are grouped by the type of GERBERcutter. Categories within each type are Head, Beam, Electrical, and Installation. There is also a listing for all GERBERcutters of consumables (spare parts), such as drill bits, knife blades, and belts. Information is stored in Adobe Acrobat PDF format for easy access. Features in the Acrobat reader include: Zoom for enlarging drawings. Search for finding a part by name or number. Print for printing out assembly drawings or part number lists.
Refer to the installation instructions that come with the CD when installing the Parts documentation and the Acrobat reader.
CAM Applications
Flexibility within the C200MT program allows you to set up your GERBERcutter based on differences in patterns, materials, and types of manufacture. When your GERBERcutter was first installed, your Field Service representative or trainer customized setup files for your manufacturing needs at that time. To achieve optimal cutting performance for a different application you should: Prepare the cut file data for automated cutting. Consider fabric, size of the pieces, and cutting sequence. See below. Select the most appropriate preset setup available in the C200MT program. Your selection should be based on fabric hardness, porosity, tendency to fuse, and ply height. Refer to the C200MT Software Users Guide. Customize vacuum settings, knife sharpening, and motion control parameters for this setup. See the next page.
Automated cutting concepts are explained briefly below. For detailed applications information, ask your Field Service representative about the availability of the CAM Applications manual. Automated Cutting Concepts The GERBERcutter is an efficient, computer aided manufacturing (CAM) system. Computer aided design (CAD) systems provide instructions in a cut file to control the cutting system. The GERBERcutter executes those commands. Parameters in the C200MT program determine exactly how those commands are executed. To improve cutting results consider the following concepts.
Data Preparation Preparation of data for a GERBERcutter differs from hand cutting in that special consideration must be given to the pattern pieces and the material being cut. An operator cutting by hand intuitively compensates for a different fabric or tattered corners on a pattern piece. Because the GERBERcutter simply follows CAD instructions, the pattern maker, digitizer, and marker maker must give consideration to some of the things mentioned below. Remember, automated cut quality is directly related to the CAD instructions. Pattern Pieces Before pattern pieces are digitized and stored, it is a good idea to answer the following questions based on the cutting results desired. Are slit, V, or both notch types going to be used? Is it permissible to miter corners? Is there an added buffer on the pattern template to compensate for hand cutting inaccuracy? If so, is it still needed? If existing pattern pieces are torn, wrinkled, or frayed, redefine making sure corners are accurate, crisp, and clean with straight lines and smooth curves. Digitizing Always define an accurate grain line. If the grain line is off in rectangular pieces, the parts will not nest with true common lines. Marker Making The marker maker should consider the placement of large and small pieces (see Vacuum Hold Down section).
Vacuum Hold Down The GERBERcutter relies upon a vacuum system to compress and stabilize the material to be cut. The size of cut pieces, material porosity, and cutting sequence affect the performance of the cutting system. You can customize a setup by changing parameters in the Vacuum Systems category. Refer to the C200MT Software Users Guide. Regularly scheduled maintenance of the vacuum system ensures optimum mechanical performance of the GERBERcutter. See chapter 6. Knife Sharpening Material content (i.e. natural or synthetic fibers, coatings, etc.) and ply heights determine knife sharpening requirements. You can customize a setup by changing parameters in the Sharpen Parameters category. Refer to the C200MT Software Users Guide. Regularly scheduled maintenance of the sharpener assembly ensures optimum mechanical performance of the GERBERcutter. See chapter 6. Motion Control Quality requirements, material, and type of manufacture must be considered when optimizing the performance of the GERBERcutter. The C200MT program has a builtin knowledge base and is flexible enough to meet the needs of Aerospace, Apparel, Automotive, Furniture and many other industrial applications. For example, if cutting tubular goods you may want to use the Clipping Window or Centerline Origin features. If cutting narrow markers, Marker Stacking may speed throughput. Refer to the C200MT Software Users Guide.
*ORVVDU\
axis
An imaginary line used to describe movement and location on the cutting table. The GERBERcutter has three axes: X (parallel to table length), Y (parallel to table width), and C (knife direction).
backlash
The space between two gears or a gear and its rack.

beam control panel (BCP)
A terminal that lets you control the cutter head and beam assembly from the cutting table. The computer that processes input from the beam control panel is called the BCC.
bite feeding
A feature on TCW and ZVC systems that matches cutter head movement with conveyor movement, permitting automatic cutting of a long spread. The spread is cut in sections that fit on the cutting table surface. Each section is called a bite.
BRISTLE SQUARE
Squares of molded bristle that plug into conveyor slats on TCW and ZVC systems or into grids on Static systems. They form a work surface for cutting material.
C200 controller
The command center of the GERBERcutter.

Caxis
An imaginary straight line that the knife rotates about.

circuit breaker
A switch that automatically interrupts an electric circuit.

command
A request entered at a terminal, such as the operator workstation, to perform a function.

config
See setup.
conveyor
Moving work surface on TCW and ZVC systems made from aluminum slats and covered with Gerber BRISTLE SQUARES.
cursor
A pointer that you see on the monitor screen of your operator workstation. Use the pointing device to move the cursor.
Glossary Page 163
cut file
A computer data file that tells the GERBERcutter how to cut out pattern pieces in a marker from a spread.
Cutter Info Database (CIDB)
An optional report generation package that helps you judge how well you are using your GERBERcutter.
data
Information stored on a disk.

default
A setting that is programmed into the computer at the factory. This is used until you override it by selecting another setting.
disk
A computer data storage medium made of plastic covered with a magnetic coating.
disk drive
A device that lets a computer read and write data on a 3.5 or a 5.25 inch disk.
downloading
Transmitting a file or program from a central computer to another computer (that is, from the operator workstation PC to the MCC).
drill
An optional unit that attaches to the cutter head for making drill hole marks.
dry haul
The distance traveled with the knife out of the fabric.

dry run
Executing a cut file without plunging the knife or drill into the material.
emergency stop (ESTOP)
A red, push button that immediately stops all GERBERcutter motion.

Energy Saving Mode (ESM)
A vacuum feature that reduces vacuum to the cutting table when the cutter has been idle for a certain period of time.
front end processor (FEP)
Another name for the operator workstation PC.

hard disk drive
A computer data storage device that holds the software that runs the GERBERcutter. A hard disk drive uses rigid metal disks to store large amounts of data.
Page 164 Glossary
hardware
Physical elements of the computer, such as the monitor and keyboard.

heel cut
Cut made by the heel of the knife. The heel is the thickest edge (following edge) of the knife blade.
initialize
Setting the X0, Y0 coordinate for the cutting table after downloading the C200MT software. The system uses this coordinate as a reference when processing a cut file.
keyboard
A device with keys, like those on a typewriter, that lets you enter data and communicate with the C200MT.
lateral drive
A table option. The cutting table can travel from one spreading table to another.
lay puller
A material handling system for Static systems.

left side
The left side of the table as seen from the takeon end.
limit switch
A switch that sets boundaries (limits) for cutter head or beam travel on the work surface of the cutting table. Limit switches also tell the C200MT when the cutter head reaches the X0, Y0 coordinate when you initialize the system.
marker
Another name for a cut file being processed on the cutter.

monitor
A device like a television that receives computer video signals and displays information on the screen.
motion control computer (MCC)
A computer that responds to instructions sent from the operator workstation PC to control cutting table motion.
network
A set of computers connected together.

network file server
A computer that provides a central database for other networked computers.
Glossary Page 165
operator workstation
The computer, monitor, and keyboard used to access the C200MT program and relay your commands, cut file data, and setup data to the Motion Control Computer (MCC) for processing.
origin
A point that represents the X0,Y0 location for the cutting table (or a marker). Every other point on the table (or on the marker) is relative to the origin point.
parameter
A setting defined in a setup file.

plenum
A sectioned chamber that is part of the vacuum system.

printer
A device for putting computer data onto paper.

program
A set of instructions for a computer to execute. The programs that direct a computer are called software.
right side
The right side of the cutting table as seen from the takeon end.
Run Time Biting
A utility that bites the marker just before the GERBERcutter processes it.
servo motor
One of several electric motors used to move the beam along the Xaxis, the cutter head along the Yaxis of the cutting table, and control knife rotation on the Caxis.
setup
A computer data file that configures the system in a particular way, depending on what materials you are cutting.
software
Set of computer programs used to run the GERBERcutter and communicate with you. These include the C200MT program and Windows NT.
spread
One or more layers of material spread on a table for the purpose of cutting out pattern pieces.
static length biting
A method of biting in which each bite has the same length. In this method, some pieces are split between bites.
Page 166 Glossary
takeoff end
The end of the cutting table where material leaves after being cut.
takeon end
The end of the cutting table that receives material for cutting.
utility
A program that helps you operate the computer. Examples include Queue Manager and File Manager.
vacuum gauge
Measures table vacuum. The vacuum pressure gauge in the Main Cutter Control screen displays the current vacuum levels.
vacuum generator
The unit that makes a vacuum which is used to hold material firmly to the table work surface during cutting.
vacuum level control
A vacuum feature that increases or reduces table vacuum depending on the current cutter mode (idle, bite, or cut).
variable length biting
A method of biting a marker so that pieces are not split between bites.
Xaxis
A horizontal reference line in a coordinate system. The Xaxis is the length of the table, from the takeon end to the takeoff end.
Yaxis
A vertical reference line in a coordinate system. The Yaxis is the width of the table, from the left (operator) side to the right (remote) side.
zoned vacuum
A vacuum feature that applies vacuum to a certain area of the cutting table. The cutting table is divided into five more zones. Vacuum can be applied to one, two, or three zones at a time depending on the pieces being cut. This feature is available only on Static and ZVC systems with pneumatic zoning.
Glossary Page 167
Page 168 Glossary
$SSHQGL[
Knife and Drill Bit Part Lists This appendix provides a list of knife blades and drill bits available from Gerber at the time this manual was printed.
Note:
For the most current information, refer to the Service Parts CDROM. Ask your local Sales and Service office about the availability of this useful tool.
Maintenance Checklists For your convenience, checklists for 8, 40, 160, and 960 hour maintenance schedules are included at the end of this appendix. See chapter 6 for detailed procedures.
Note:
To keep an electronic record of scheduled maintenance, use the checklists available in the Training CBT feature. Ask your local Sales and Service office about the availability of this CDROM.
Appendix Page 169
Knife Blades for S91 GERBERcutters

Various knife widths are available for your GERBERcutter. For example, 0.125 knives are recommended for cutting heavy duty materials, such as denim while carbide knives are used for Aerospace applications. In addition to the knives described below, there is an optional knife setup for lingerie.
Note:
Changing to a different knife width may require changing additional parts in the knife drive train and the sharpener assembly. Check with your Field Service representative.
Description 0.093 x 5/16 x 10 1/16, Hollow Ground, M2 Steel 0.093 x 5/16 x 10 1/16, Flat Ground, M2 Steel 0.093 x 5/16 x 10 1/16, Flat Ground, GKS 45 0.093 x 5/16 x 10 1/16, Hollow Ground 0.093 x 5/16 x 10 1/16, Flat Ground 0.093 x 5/16 x 10 1/16, Cryogenic Treated Knife 0.093 x 0.250 x 10 1/16, Flat Ground, M2 HS Steel, Silk Blade 0.093 x 0.250 x 10 1/16, Hollow Ground, M2 HS Steel, Silk Blade 0.093 x 0.250 x 10 1/16, Flat Ground, GKS 45, Silk Blade GGT Part Number 021261008 021261009 021261010 021261011 021261012 032426000 078798003 078798004 078798005 022217005 022217006 022217007 032419010 032419011 032419012 039536003 039536004 039536005 034325000 044274000
Knife Width 0.093 Knives
0.078 Knives
0.078 x 0.200 x 10.00, Flat Ground, M2 HS Steel 0.078 x 0.200 x 10.00, Hollow Ground, M2 HS Steel 0.078 x 0.200 x 10.00, Flat Ground, GKS 45
0.125 Knives
0.385 x 0.125 x 10.00, Hollow Ground, M2 HS Steel 0.385 x 0.125 x 10.00, Flat Ground, M2 HS Steel 0.385 x 0.125 x 10.00, Flat Ground, GKS 45 0.385 x 0.125 x 10.00, Hollow Ground, M2 HS Steel 0.385 x 0.125 x 10.00, Flat Ground, M2 HS Steel, Service Only 0.385 x 0.125 x 10.00, Flat Ground, GKS 45
Carbide Knives
0.0625 x 0.188 x 2.00, Carbide Grade K68 0.0625 x 0.188 x 2.00, Carbide Grade Ramet #1 Ultra Fine
Page 170 Appendix
Drill Bits, Ejectors, and Collets for S91 GERBERcutters

Note:
Changing to a drill bit with a different diameter requires changing additional parts in the drill assembly. Larger diameter drill bits also require an ejector. Check with your Field Service representative.
GGT Part Number Ejector Rod Upper Collet Lower Collet 945500274 945500274 945500274 024348001 5/64 945500274 945500274 945500274 024348002 7/64 024348003 9/64 024348004 11/64 024348004 11/64 024348004 11/64 024348004 11/64 024348004 11/64 060136000 060136000 060136002 060136001 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 945500274 021746001 021746001 Presser Foot
Description & Diameter solid 3/64 (0.047)(1.19 mm) groove 5/64 (0.078)(1.98 mm) (1/2) rnd 3/32 (0.093) (2.36 mm) hollow 3/32 (0.093)(2.36 mm) (1/2) rnd 1/8 (0.125)(3.17 mm) hollow 1/8 (0.125)(3.17 mm) hollow 5/32 (0.156)(3.96 mm) hollow 3/16 (0.187)(4.75 mm) hollow 0.197 (5 mm) hollow 1/4 (0.250)(6.35 mm) hollow 5/16 (0.313)(7.95 mm) hollow 3/8 (0.375)(9.53 mm) hollow1/2 (0.500)(12.7 mm) hollow 19/32 (0.591) (15.01 mm) hollow 21/32 (0.666)(17 mm) hollow 3/4 (0.787)(20 mm)
Drill 044330000 030595003 030595002 024351001 030595001 024351002 024351003 024351004 075782000 072490000 072490001 031199004 031199003 031199005 031199007 031199006
Bushing 021706013 021706007 021706002 021706004 021706001 021706003 021706005 021706006 021706014 021706008 021706010 021706011 021706009 060137000 064356001 064356000
Appendix Page 171
8 Hour Maintenance Schedule Checklist

See pages 79 through 83 for procedures. To keep an electronic record of scheduled maintenance, use the checklists available in the Training CBT feature. Initials/Date Check knife yaw alignment Check knife offset alignment Check Knife Intelligence alignment Fill the tension arm oil cups Fill the pivot arm oil cup Clean and film coat the air cylinder rod for the elevator Clean and film coat the elevator guide rods Clean and lubricate the swivel assembly Clean and lubricate the cutter tube Clean and lubricate the knife articulating arm Perform sharpener assembly maintenance Clean and film coat the knife presser foot guide rods Clean and film coat the air cylinder rod for the knife presser foot Clean and film coat the drill(s) up/down air cylinder Clean and film coat the air cylinder rods for the drill presser foot Clean and film coat the Yaxis roundway Clean and film coat the Yaxis squareway Clean and film coat the Xaxis roundways Check the Xaxis racks Clean the vacuum intake filter Check for fluid in air/reducer filters _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________ _____________
Page 172 Appendix

See pages 85 through 89 for procedures. To keep an electronic record of scheduled maintenance, use the checklists available in the Training CBT feature. Initials/Date Check the Caxis drive belt Clean, lubricate, and check the Caxis servo gearing Check tension of the knife drive belts Check mechanical alignment of the knife Check the head upper stop Check the head lower stop Check tension of the drill drive belt(s) Clean, lubricate, and check the first Xaxis pinion gearing Clean, lubricate, and check the first Xaxis servo gearing Clean, lubricate, and check the Yaxis countershaft gearing Clean, lubricate, and check the Yaxis servo gearing Clean, lubricate, and check the second Xaxis pinion gearing Clean, lubricate, and check the second Xaxis servo gearing Check the torque tube drive belts Clean, lubricate, and check the wheel housing cam rollers Clean and lubricate the first Xaxis wheel assembly Clean and lubricate the second Xaxis wheel assembly Clean and inspect the bite encoder wheel Perform Xaxis spring scale test Perform Yaxis spring scale test ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________
Clean and film coat the clamp bar air cylinders (TCW) Clean and film coat the resealer air cylinder rods (TCW) Check resealer bar up/down air flow adjustment (TCW)
______________ ______________ ______________
Appendix Page 173

See pages 91 through 95 for procedures. To keep an electronic record of scheduled maintenance, use the checklists available in the Training CBT feature.
Initials/Date Check the knife speed adjustment (should be OK for one year) Check the drill speed adjustment (should be OK for one year) Check the Yaxis roundway bearings Check the Yaxis squareway bearings Check tension of the Yaxis belt Check if the beam is square Check the vacuum generator belts Clean the vacuum stack filter ______________ ______________ ______________ ______________ ______________ ______________ ______________ ______________
Check the conveyor drive alignment (TCW and ZVC) Check the lay puller drive alignment (Static)
______________ ______________
Page 174 Appendix

See pages 97 through 102 for procedures. To keep an electronic record of scheduled maintenance, use the checklists available in the Training CBT feature.
Initials/Date Check the knife motor bushings Check the drill motor bushings Lubricate the vacuum motor Lubricate the Spencer vacuum turbine Lubricate the Hoffman vacuum blower Check alignment of the coupling for Hoffman blower ______________ ______________ ______________ ______________ ______________ ______________
Check fluid level of the conveyor gear box (TCW and ZVC) Change every third time Check fluid level of the lay puller gear box (Static) Change every third time Check fluid level of the surface cleaner gear box (TCW) Change every third time Lubricate the surface cleaner pillow block bearing (TCW) Lubricate the platform drive cam roller bearings (TCW) Clean and lubricate the platform drive chain (TCW) Lubricate the platform drive sprocket bearings (TCW) Check fluid level of the platform drive gear box (TCW) Change every third time Lubricate the platform drive shaft bearings (TCW) Lubricate the platform wheel cam roller bearings (TCW)
______________ ______________ ______________ ______________ ______________ ______________ _____________ ______________ ______________ ______________ ______________ ______________ ______________ ______________
Check the roller and clamps for overhead cable trolley (TCW) ______________
Appendix Page 175
Page 176 Appendix
,QGH[
A
Air/Reducer Filter, 83, 135 Alignment coupling for vacuum assembly, 99, 137 conveyor drive, 95, 139 lay puller drive, 95, 140 See also Knife Alignment Applications, 159 Bristle Penetration, 112 BRISTLE SQUARES, 5, 130 rearranging, 131
C
C Home to System Zero Diagnostic, 154 C200 Controller, 3 C200MT, 25 accessing, 30 exiting, 41 CAM Applications, 160 Categories parameter, 52 Caxis, 20 drive belt, 85, 113 servo gear, 85, 113 yaw alignment, 79 Check Origin, 43 CIDB, 18, 60 Circuit Breaker, 10 turn off, 41 Clamp Bar, 89, 138 position first bite, 33 Cleaner solvents, 74 work surface, 132 Collet part numbers, 171 Config. See Setup Conveyor controls, 11 drive alignment, 95, 139 gear box, 99, 139 position first bite, 33 Coupling alignment, 99, 137 vacuum blower, 135 Covers, 103, 122, 135 CTOT, 17 Cut File, 25 opening, 36 Cutter Head, 4, 103 See also Head Cutting basic steps, 29
B
BCP, 13 Beam, 4 maintenance, 82, 87, 92, 121 square, 93, 129 wheel assemblies, 125 wheel housing cam rollers, 125 See also Xaxis See also Yaxis Beam Control Panel, 13 cover, 122 Beam Square Test, 156 Bearings platform drive, 101 roundway, 126 squareway, 126 surface cleaner pillow block, 132 Belt Caxis drive, 85, 113 drill drive, 87, 118 knife drive, 86, 114 torque tube, 88, 123 vacuum drive, 93, 136 Yaxis drive, 93, 128 Bite, 23 pause between, 43 run time, 54 static length, 54 variable length, 54 Bite Encoder, 89, 125 Blower vacuum, 94, 98, 136
Bristle Locating Guides, 131
Index Page 177
speed, 39 Cutview, 56
D
Data Preparation, 160 Data Scale Factor, 44 Diagnostics, 149 Beam Square Test, 156 C Home to System Zero, 154 Cut Tests, 155 Heel to Heel Test, 157 Input Output Test (DG 23), 151 KI Calibration, 152 Knife Offset Setup, 158 Drill, 17 air cylinder rods, 81 belt, 87, 118 bit, 116, 171 collet, 171 drive belt, 118 drive motor, 119 ejector rod, 116, 171 motor brushes, 97, 119 part numbers, 171 speed, 92, 119
FEP, 15 File Manager, 58 Filters, 134 air/reducer, 83, 135 stack, 83, 134 vacuum, 82, 134 Flywheel Stroke, 86, 112
G
Gear knife drive, 114 X and Yaxis servo, 123 Xaxis pinon, 123 Yaxis countershaft, 124 Gear Box conveyor drive, 139 lay puller, 140 work surface cleaner, 132
H
Head cover, 103 lower stop, 86, 112 maintenance, 79, 85, 91, 97, 103 upper stop, 86, 112 Heel to Heel Test, 86, 111, 157
E
Elevator, 112 air cylinder rod, 80 guide rods, 80, 112 head stops, 86, 112 End Cap cover, 122 Ejector Rod, 116 part numbers, 171 Error Messages, 144 EStop, 9 plungers, 9 switches, 8 Exiting, 41
I
Initialize, 32 Input Output Test (DG 23), 151
J
Jog controls, 12 position first bite, 33 See also Conveyor See also Lay Puller
F
Fabric Alignment, 42 Feed Rate, 30
K
KI Calibration (DG 20), 152
Page 178 Index
Knife, 106 bristle penetration, 86, 112 part numbers, 170 reset for new, 65 setting speeds, 66 sharpen, 63, 162 speed, 91, 115 Knife Alignment mechanical offset, 86, 111, 156 offset, 79, 158 yaw, 79, 154 Knife Drive belt, 86, 114 motor brushes, 97, 115 tension and pivot arms, 80, 113 Knife Drive Train articulating arm, 80, 105 cutter tube, 80, 105 swivel assembly, 80, 105 Knife Guides, 110 Knife Presser Foot, 108 air cylinder rod, 81 Knife Intelligence, 67 alignment, 79 calibration, 152 null, 67 Knife Motor turn on, 39 Knife Offset Setup, 157
L
Laser Light safety, xiv, 72 turn on, 37 Lay Puller drive alignment, 95, 140 gear box, 99, 140 position first bite, 33 tow bar, 33 Limit Switches, 7, 32 Lubricants, 74
advanced X and Yaxis, 126 basic X and Yaxis, 122 beam, 82, 87, 92, 121 Caxis, 85, 113 cleaning, 74 drill, 81, 87, 92, 97, 116 electrical, 73 elevator, 80, 86, 112 filters, 82, 83, 94, 134 head, 79, 85, 91, 97, 103 knife, 106 knife drive, 80, 86, 114 knife drive train, 80, 104 lubrication, 74 material handling systems, 99, 138 platform, 100, 141 safety, 72 roundway and squareway, 82, 92, 121 roundways and racks, 82, 133 sharpener assembly, 81, 107 table, 82, 89, 93, 99 tools, 75 vacuum, 82, 93, 98, 135 work surface, 130 Maintenance Schedule 160 hour, 91, 174 40 hour, 85, 173 8 hour, 79, 172 960 hour, 97, 175 Marker, 36 Marker Report, 60 Material Handling Systems, 138 Motor drill drive, 97, 119 knife drive, 97, 115 vacuum, 98, 136
O
Operator Workstation PC, 15 Origin, 21 check, 43
M
Maintenance, 71
restore, 50 set for cut file, 38 Overhead Cable Trolley, 102
Index Page 179
Overlay, 33
P
Parameter categories, 52 manager, 52 Parts numbers for drill, 171 numbers for knife, 170 order, 74 service CD, 159 Path Intelligence, 69 Pause Between Bites, 43 Piece Recut, 49 Piece Search, 49 Platform controls, 11 drive maintenance, 101, 141 Ply Height conveyor drive alignment, 139 lay puller drive alignment, 140 maximum, 28 POWER Processor, 18 Power Up, 30 PreProcessor, 55 Processing cut file, 40 Product Support, xi, 74, 143
Restore State, 47 manual, 48 Right Side Option, 17 initialize, 32 Roundway, 82, 122 bearings, 126 Roundways, 133 Run Time Biting, 54
S
S91 models available, 1 Static, 2, 77 TCW, 1, 76 ZVC, 2, 77 Safety, xiii, 72 Service Parts, 159 Servo Power Enable, 31 Setup, 25 change, 52 selecting, 35 Sharpener Assembly, 81, 107 knife presser foot, 81, 108 Shift Report, 61 Shut Down, 41 Software, 25 Squareway, 82, 121 Squaring the Beam, 129 Stack filter, 94, 134 Spread, 28 Spring Scale Test, 89, 127 Static, 2, 77 Support. See Product Support Surface Cleaner gear box, 100, 132 pillow block bearings, 98, 132 Switches, 7 EStop, 8 knife, 30 limit, 30
Q
Queue Manager, 57
R
Racks, 82, 133 plastic film caution, 33 Recovery, 46 before, 46 Bite Search, 50 Piece Recut, 49 Piece Search, 49
T
Restore Origin, 50 Restore State, 47 Reports, 61 Resealer, 89, 138 Table, 130 maintenance, 82, 89, 93, 98, 130 Takeoff End, 19 Takeon End, 19
Page 180 Index
TCW, 1, 76 Tool Codes, 56 Tools, 75 Torque Tube, 88, 123 Training (CBT), 159 Trim Cut, 45 Troubleshooting diagnostics, 149 error messages, 144 Turbine. See Vacuum Turn On, 30
platform drive, 101 Windows NT, 25 Work Surface, 5, 130 Work Surface Cleaner, 132 gear box, 99, 132
X
Xaxis, 20 cam rollers, 88, 125 pinion gear, 87, 123 racks, 82, 133 roundways, 82, 133 servo gear, 87, 123 spring scale test, 89, 127 torque tube, 88, 123 wheel assemblies, 88, 125
U
Underlay, 28 Utilities C200MT, 51
V
Vacuum, 6 energy savings mode, 70 hold down for application, 161 readout, 11 turn on, 37 Vacuum Maintenance blower, 94, 136 blower lubrication, 98 coupling alignment, 99, 137 coupling guard, 135 belts, 93, 136 filter, 82, 94, 134 generator, 93, 136 jack shaft cover, 135 motor, 98, 136 takeon cover, 135 turbine, 98, 136 View Marker, 56
Y
Yaxis, 20 bearings, 92, 126 belt, 93, 128 countershaft gear, 87, 124 servo gear, 87, 123 spring scale test, 89, 127
Z
ZVC, 2, 77
W
Wheel assemblies, 88, 125 housing cam rollers, 88, 125
Index Page 181
Page 182 Index
U.S.A./CANADA Gerber Garment Technology, Inc. WORLD HEADQUARTERS P Box 769 .O. 24 Industrial Park Road West Tolland, Connecticut 06084 USA TEL: (860) 871-8082 FAX: (860) 871-6007
INTERNATIONAL Gerber Garment Technology, Inc. INTERNATIONAL DIVISION P Box 769 .O. 24 Industrial Park Road West Tolland, Connecticut 06084 USA TEL: (860) 871-8082 TLX: 192558 GGTIHQ FAX: (860) 872-6742
EUROPE GGT Europe N.V./S.A. Excelsiorlaan 55 B-1930 Zaventem, BELGIUM TEL: (32) (2) 716 03 11 FAX: (32) (2) 716 03 22
P/N 083878000 Printed in USA 2/98

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S-91 GERBERcutter

OPERATOR AND MAINTENANCE MANUAL

5 Optimizing Cutter Performance

Glossary ............................................................................................................163 Appendix ...........................................................................................................169

xii Whats Inside

Failure to follow these safety precautions could result in injury or death.

Dangerous Procedure Warnings

Safety Precautions xiii

xiv Safety Precautions

xvi Safety Precautions

Platform and Conveyor Controls

Chapter 1 S91 GERBERcutters Page 1

Stationary Work Surface

Page 2 Chapter 1 S91 GERBERcutters

Chapter 1 S91 GERBERcutters Page 3

Cutter Head Beam Control Panel Beam Assembly

Work Surface Laser Light Operator Workstation

Page 4 Chapter 1 S91 GERBERcutters

BRISTLE SQUARES with Grids

BRISTLE SQUARES with Slats

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BRISTLE SQUARES and Slats

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Circuit Breaker 2 (behind door) Hazard Symbol

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Flat Panel on Static Cutter

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EStop Icon Keys Servo Power Enable

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Conveyor and Platform Controls

Beam Control Panel

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Direction and Location

Right Side (Far Side)

Takeoff End (ZVC / TCW) Left End (Static)

Takeon End (Right End on Static)

Beam Control Panel

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Location is also given in terms of the X and Yaxes, as shown below.

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Software and Files

Setups were previously called Configuration or Config files.

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Chapter 3 Cutting Markers Page 27

To spread material on the spreading table

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1. Turn on cutter 2. Enable servo power

4. Position first bite 5. Select setup

7. Turn on vacuum 8. Turn on laser

9. Position laser light