Gerber ADVANTAGE ROUTER 600 Owner's Manual
ADVANTAGE ROUTER 600
USER MANUAL
not specified.
Manchester, Connecticut 06040
Error! Switch argument
151 Batson Drive
U.S.A.
Document P54225A Rev A
COPYRIGHT NOTICE
COPYRIGHT 1994 Gerber Scientific Products, Inc. All Rights Reserved.
This document may not be reproduced by any means, in whole or in part, without
written permission of the copyright owner.
This document is furnished to support the Advantage Router 600. In
consideration of the furnishing of the information contained in this document, the
party to whom it is given assumes its custody and control and agrees to the
following:
1. The information herein contained is given in confidence, and any part
thereof shall not be copied or reproduced without written consent of Gerber
Scientific Products, 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 of this
document shall not constitute any right or license to do so.
PRINTED IN U.S.A.
ADVANTAGE Router and ART Path are trademarks of Gerber Scientific Products, Inc.
GRAPHIX ADVANTAGE is a registered trademark of Gerber Scientific Products, Inc.
Sears Craftsman is a trademark of Sears, Roebuck, and Company.
3-in-1 is a registered trademark of Boyle-Midway, Inc.
FCC NOTICE
This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment
is operated in a commercial environment. This equipment generates, uses, and
can radiate radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to
cause harmful interference in which case the user will be required to correct the
interference at his own risk.
This digital apparatus does not exceed the Class B limits for radio noise
emissions from digital apparatus set out in the Radio Interference Regulations of
the Canadian Department of Communications.
Le present appareil numerique n'emet pas de bruits radioelectriques depassant
les limites applicables aux appareils numeriques de la classe B prescrites dans
les Reglements sur le brouillage radioelectrique edicte par le Ministere des
Communications du Canada.
Table of Contents
INTRODUCTION............................................................................1
Manual Contents............................................................................2
Conventions ...................................................................................2
ROUTER REQUIREMENTS ..........................................................3
System Specifications....................................................................3
Electrical...................................................................................3
Compressed Air........................................................................3
Router Table.............................................................................3
Electrical Cabinet .....................................................................3
Router Package Contents..............................................................4
Tool Kit Contents............................................................................5
SAFETY GUIDELINES ..................................................................7
OPERATING PRINCIPLES ...........................................................9
Overview ........................................................................................9
X, Y, Z Axes .................................................................................10
Z Axis ...........................................................................................12
Job Home Position.......................................................................13
Power Switches............................................................................14
Main Power Switch.................................................................14
Emergency Power Switches...................................................14
Restoring Power...........................................................................15
Router Motor Power Switch..........................................................15
ARC Box (Router Control Station)................................................16
Overview.................................................................................16
Front Panel.............................................................................17
Display Panel .........................................................................17
Function Keys...............................................................................19
Arrow Keys.............................................................................19
Start/Stop .....................................................................................20
Start Mode..............................................................................20
Start Ready ............................................................................21
Start Job.................................................................................21
Stop Mode..............................................................................22
Stop Ready............................................................................. 22
Stop Job.................................................................................23
Resume Processing ...............................................................23
Change Tools.........................................................................23
Repeat Job.............................................................................24
Reset............................................................................................25
In Menu Select Mode .............................................................25
In Other Modes.......................................................................25
Z INIT ...........................................................................................26
Perform Z Init..........................................................................26
Enter.............................................................................................28
Select ...........................................................................................29
Using Select...........................................................................29
Absolute X,Y:..........................................................................31
Set Job Home.........................................................................32
Job Home Position And Job Boundaries................................35
Return Home..........................................................................36
Feed Rate:..............................................................................37
Motor Delay:...........................................................................39
Test ........................................................................................40
Display....................................................................................41
Default....................................................................................43
EQUIPMENT INSTALLATION.....................................................45
Chip Removal System..................................................................45
Overview.................................................................................45
Install The Vacuum Shroud....................................................46
Connect The Vacuum To The Router.....................................47
SYSTEM PREPARATION AND USE ..........................................49
Tool Selection...............................................................................50
Pens And Scribe Tools...........................................................50
Engraving Tools .....................................................................50
Cutting Tools..........................................................................51
Tool Information ...........................................................................52
Collets ..........................................................................................53
Tool Installation............................................................................54
Tool Removal...............................................................................57
Tool Replacement........................................................................58
Replacement Cutters....................................................................59
Material Selection and Preparation..............................................60
Routable Materials .................................................................60
Choosing Sacrificial Material..................................................61
Attaching the Workpiece to Sacrificial Material............................62
Hard Metals............................................................................62
Thin Metals.............................................................................63
Non-Metals.............................................................................63
Using Tape.............................................................................64
Using Spray Adhesive............................................................65
Mounting the Workpiece...............................................................66
Using Clamps.........................................................................66
Drawing ..................................................................................66
Cutting....................................................................................66
Clamping the Material ..................................................................67
Using the Chip Removal System..................................................70
Pressure Foot And Pressure Foot Pad ..................................71
Using the Mist Coolant System....................................................73
CLEANING AND MAINTENANCE ..............................................75
Daily Inspection............................................................................76
Daily Cleaning..............................................................................77
Supplies..................................................................................77
Cleaning the AR600.....................................................................78
Work Table.............................................................................78
End Housings.........................................................................78
X Axis Motor Gears ................................................................79
Y Axis Motor Gears ................................................................81
Belt Wipers.............................................................................83
Replacing Belt Wipers............................................................83
End Housing Linear Bearing Seals ........................................84
Y Ways...................................................................................85
Y Belts....................................................................................85
X Ways...................................................................................86
X Belt......................................................................................86
Router Motor Linear Bearing Seals........................................87
Mist Coolant Tank and Nozzle .....................................................88
Check Mist Coolant ................................................................88
Clean Mist Coolant Nozzle.....................................................88
Weekly Inspection........................................................................89
Weekly Cleaning ..........................................................................90
Z Axis Ways ...........................................................................90
Router Motor Chip Shield.......................................................92
Electrical Cabinet Air Filters...................................................93
Table Surfacing............................................................................95
Feed And Depth Per Pass Values..........................................99
INDEX ........................................................................................103
INTRODUCTION
The ADVANTAGE Router 600 can provide all the lettering and
graphic design capabilities of the GRAPHIX ADVANTAGE
Composer to dimensional signage.
The ART Path Software Option enables the GRAPHIX
ADVANTAGE to fully control the router operation. The user routs
jobs directly from the GRAPHIX ADVANTAGE through the Router
Control Station (ARC Box) communicator. The ADVANTAGE
Router can cut designs from a wide variety of materials, as well as
scribe, engrave, or draw all types of text or graphics.
This manual provides instructions in safety, operation, and
maintenance for the ADVANTAGE Router 600, referred to as
AR600.
Your ADVANTAGE Router is a computer-controlled machine
tool, and should be operated only by trained operators. The
safety guidelines in this manual must be followed at all times
to avoid risk of injury.
®
2 ADVANTAGE Router
Manual Contents
This manual covers the basic information needed for using the
AR600. It is arranged as follows:
Requirements and package contents
Safety guidelines
Principles of operation
Basic system preparation and use
Cleaning and maintenance procedures
Conventions
The following conventions are used in this manual:
Note: A note contains important information which could affect
successful completion of a task.
CAUTION: A caution statement contains information which, if
not observed, could result in damage to the equipment.
WARNING: A warning statement contains information which,
if not observed, could result in personal injury.
ROUTER REQUIREMENTS
System Specifications
The purchase of a Router 600 includes complete unpacking,
installation, and testing performed by Gerber Field Service when
installed within the continental United States.
However, the system does have specific work area, power, and
compressed air requirements which must be supplied before
Gerber Field Service can uncrate and install the system.
ELECTRICAL
A 208, 230, or 250 V single-phase 20 Amp circuit (47/63 Hz) on a
dedicated line. Gerber supplies a receptacle to be installed by a
licensed electrician.
COMPRESSED AIR
The mist coolant system requires 0.5 CFM at 40 to 90 psi, which
can be supplied by a 1/4 to 1/2 horsepower compressor.
ROUTER TABLE
100" (2,500mm) wide x 140" (3,500mm) long x 54" (1,350mm)
high (assembled).
ELECTRICAL CABINET
18" (450mm) wide x 33" (825mm) long x 32" (800mm) high.
4 ADVANTAGE Router
Router Package Contents
The Router 600 is packed in four crates. Check each part against
the list and inspect all parts for any damage which may have
occurred during shipping.
Crate 1 (Packaged Beam Assembly):
1 Beam assembly
Crate 2 (Packaged Large Components):
5 Cross member machining
8 Angle support machining
4 Leg assembly
Crate 3 (Packaged Frame and Table Top):
1 Left side frame assembly
1 Right side frame assembly
1 Frame cable assembly
12 Router 600 table top assemblies
2 Table end machining
1 Cable support plate
1 Cable guide
Crate 4 (Packaged Small Components):
1 Accessory kit
1 Electrical cabinet assembly
1 Hardware kit
1 1 gallon coolant tank
1 Router Control Station (ARC Box)
1 3 1/4 hp motor
1 Hose and cable guard box
1 GRAPHIX ADVANTAGE interface components
1 Vacuum shroud and pressure foot
1 Hose channel assembly
Router Requirements 5
Tool Kit Contents
Tool Kit contents are listed below and are identified in the
photograph. Metric sizes are shown in parenthesis
3 1/4" (6 mm) 2-spiral flute bit, solid carbide endmill cutters
3 1/8" (3 mm) 2-spiral flute bit, solid carbide endmill cutters
1 7/8" carbide V cutter
1 3/4" carbide ball cutter
1 Scribe tool
1 Pen tool
8 Knob and screw assemblies
8 "T" nuts
6 Work clamps
1 Tool height gage
1 Step height gage
1 1/4" socket coupling hose
1 1/4" plug coupling hose
1 1/8" tool collet adapter
1 1/4"(3 mm) tool collet
1 1/2" (6 mm) tool collet
1 Collet wrench set
4 Spare fuses
6 ADVANTAGE Router
SAFETY GUIDELINES
WARNING: The ADVANTAGE Router is a high-speed cutting
machine which throws out chips of metal, wood, or plastic.
Its use may be hazardous if you do not observe the following
precautions. These guidelines are necessary for the safe and
efficient operation of the ADVANTAGE Router.
WARNING: Do not store wet aluminum chips in a closed
container and do not use the vacuum hose to clean up wet
aluminum. Wet aluminum produces hydrogen gas. This gas
may reach explosive concentrations when wet aluminum
chips are stored in a closed container.
1. Only a trained operator should attempt to run the equipment.
2. Do not use the router in a damp or wet location.
3. Stand in front of the ARC box during system operation to
provide easy access to the RESET key and the system power
circuit breaker. This also prevents any clothing from getting
caught in the machine.
4. Keep the work area clear for easy access to the emergency
stop switches. These are located at each end of the router
table beam.
5. Turn the router motor OFF or unplug the router when changing
tools.
6. Wear protective eyewear, such as goggles or safety glasses,
to cover the front and sides of the face.
7. Tie back or cover long hair.
8. Remove loose jewelry, ties, and loose clothing. Wearing a
long-sleeved shop coat is strongly recommended.
8 ADVANTAGE Router
9. Wear ear protection.
10. Do not operate the machine with the electrical cabinet doors
open. Doing so will expose high voltage circuitry to material
chips and affect cooling airflow.
11. Keep all personnel at a safe distance from the machine when
it is operating.
12. Carefully secure the workpiece with clamps.
13. Use the proper tool for the material. Do not use small tools
with heavy material.
14. Make a test cut whenever possible to test the tool in the
material.
15. Perform all periodic maintenance procedures on a regular
basis.
OPERATING PRINCIPLES
Overview
The ADVANTAGE Router 600 consists of these major
components:
the Router Table, which includes the work table, the beam,
and the router motor carriage
the electrical cabinet
the Router Control Station, also called the ARC Box, which
controls the start, stop, slew, Z initialization, and job home
position functions.
Text and graphics are cut, engraved, scribed, or drawn at the
router table after being created and sent from the GRAPHIX
ADVANTAGE system.
During router operation, the cutting table and clamped workpiece
remain stationary. All operating motion is performed by the router
motor, beam and tool.
Note: It is essential to read this section before trying to operate
the ADVANTAGE Router. This section introduces the operating
principles of the router system.
10 ADVANTAGE Router
X, Y, Z Axes
The ADVANTAGE Router 600 has three basic axes of movement:
The X (horizontal) axis is oriented from left to right.
The Y (horizontal) axis is oriented from front to back.
The Z (vertical depth) axis is oriented up and down.
When the router cuts a sign, the tool moves in the X, Y and Z axes
of movement.
Operating Principles 11
References in this manual to "travel limits" refer to the size of the
table in the X and Y axes of movement unless otherwise specified.
12 ADVANTAGE Router
Z Axis
The Z Axis of the router is the up and down movement of the tool.
The Z Axis represents the thickness of the material, the cutting
depth, the engraving depth, or, when drawing, the amount of
downward pressure on the pen.
This axis of movement is controlled by:
the Z INIT function key
a Z Axis adjustment knob located above the router motor
the ART Path depth of cut.
Initializing the Z Axis is an essential procedure when using the
ADVANTAGE Router 600. It establishes the location of the tool
above the workpiece initially or at the start of a job.
Note: The Z Axis must be initialized every time the tool or material
is changed, and whenever the operator prepares to cut, draw, or
engrave. Failure to initialize the Z Axis properly will cause the
machine to cut at the wrong depth. This may destroy the material
and cause the tool to cut into the router table.
The workpiece and sacrificial material must be mounted on the
router table when the Z Axis is initialized. See the Z INIT portion
in the ARC Box section in this manual for instructions on
initializing the Z Axis.
Operating Principles 13
Job Home Position
The job home position is the position on the router table that
corresponds to the job 0,0 point or starting position of the job. The
job home position is stored in the ARC Box and is maintained
even when power is interrupted.
The job home position (start position) is also controlled by ART
Path. ART Path considers the current tool position to be job
home. The actual job starting position may be modified by a
preposition (either absolute or relative) set in the ART Path Output
dialog box.
The SET JOB HOME ARC Box function allows the router operator
to modify the home position after a job has been received at the
ARC Box and the job header, material and tool messages have
been displayed.
The job home position of each job is stored when the job starts.
The RETURN HOME ARC Box function returns the carriage to the
stored job home position. In the event of a power failure or other
job interruption, the operator can use the RETURN HOME
function to return the router carriage easily to the stored home
position. This also simplifies starting multiple jobs from the same
position.
See the SET JOB HOME and RETURN HOME descriptions in the
ARC Box section of this manual for more information. Also see
the ART Path User Manual for information on job positioning.
14 ADVANTAGE Router
Power Switches
MAIN POWER SWITCH
This power switch turns the router power on and off.
The Router 600 main power switch is located on the front panel of
the electrical cabinet.
Before turning on the main power switch, make sure that the
control station power supply is connected to both the control
station and the appropriate grounded outlet.
EMERGENCY POWER SWITCHES
The emergency stop switches look like red "mushrooms". If an
emergency occurs, the operator can stop the router instantly by
pressing the emergency stop switch.
The Router 600 table has two emergency power switches located
on top of each beam end housing.
Operating Principles 15
Restoring Power
The emergency power switches turn off all power to the router.
Restore power by turning on the main power switch specific to
each router.
The router table emergency power switches on the Router 600
cannot be used to turn the router power on.
Router Motor Power Switch
The router motor power switch turns the motor on and off. The
router motor has a thumb switch on the top labeled ON and OFF.
CAUTION: The router motor switch should be off until the job
is ready to begin.
plotting or scribing.
The router motor must be OFF during vacuum shroud
installation, tool changing, Z Axis initialization, or when
performing any other functions around the cutter.
DO NOT turn the router motor on when pen
When the job is ready to begin, turn ON the router motor power
switch.
Press the START key to start the job.
Note: There is a delay before the tool begins cutting. This delay
gives the router motor time to come up to full speed before cutting
begins, and the operator time to stop the job if the router motor is
not ON.
16 ADVANTAGE Router
ARC Box (Router Control Station)
OVERVIEW
The ARC Box is the communication link between the GRAPHIX
ADVANTAGE and the router system. It can:
send and receive messages and commands to and from the
GRAPHIX ADVANTAGE
display messages to the operator
control router motor movements
change feed rates
return the router carriage to the job home position
set motor delay
Operating Principles 17
FRONT PANEL
The front panel of the ARC Box consists of a message display
panel and nine function keys:
START/STOP
RESET
Z INIT
SELECT
right, left, up, and down arrow keys.
The ENTER key is not used.
DISPLAY PANEL
The bottom right of the message display panel may contain four
indicators for the operator:
W, w - Alternating uppercase and lowercase indicates that
the router is waiting for a job.
J, j - Alternating uppercase and lowercase indicates that
there is a job ready for routing. Pressing START will begin or
continue processing the job.
I, i - Alternating uppercase and lower case indicates the job
is incomplete, which occurs when a partial job is sent from
ART Path. Power interruption at the GRAPHIX ADVANTAGE
or a pause status in the Plot Spooler application will cause
partial transmission.
WARNING: When the incomplete job indicator (I,i) and
START JOB are displayed, the router may move without
further warning.
The top right of the message display panel at times may contain
an asterisk (*). When a job is running and the operator presses
the STOP key, the asterisk appears to show that the machine has
received the message and will stop at the next logical point.
18 ADVANTAGE Router
Power-Up Tests
When the power is turned ON, the ARC Box performs diagnostic
self-tests, and displays the operating set revision level. If the
Advantage router is equipped with the job home feature, the ARC
Box requests the operator to slew the motor carriage near the
point of orientation, which is the absolute 0,0 point. To slew to the
point of orientation, use the arrow keys to move the motor carriage
as far toward the front and to the left as possible.
When the carriage is at 0,0, the carriage will move away from the
limit a preset distance in X and Y. The ORIENTATION message
will appear in the display panel, followed by the STOP READY
message.
If an error occurs:
The system emits a constant audible tone.
Press the RESET key to clear the error and to rerun the failed
test(s).
If the same error recurs or if RAM ERROR, ROM ERROR, or
INTR_ERROR is displayed, contact the Router Support Group
at 800-336-1698 (USA and Canada).
When testing successfully completes, the STOP READY message
displays.
Operating Principles 19
Function Keys
The function keys located on the front panel of the ARC Box
perform specific routines. Each function key is discussed
individually in the following pages.
ARROW KEYS
The arrow keys are most frequently used to slew the router
carriage into position. Slewing refers to positioning the X
and Y axes where desired.
The arrow keys are also used to scroll through available
choices after a selection has been made in the Menu Select
mode. See the page in this section on Menu Select mode.
To slew the carriage
To position the tool to the left or right over the router table
surface, press the left or right arrow keys until the desired
placement is reached.
To position the tool forward or backward over the table
surface, press the up or down arrow keys until the desired
placement is reached.
To slew diagonally, press two keys at the same time (left or
right with up or down).
You cannot slew past the table edges if the router is equipped
with the limit switch feature.
20 ADVANTAGE Router
Start/Stop
This key toggles between the START and STOP modes.
START MODE
START mode, as shown by a message in the display panel, may
be in one of two states:
START READY - the system is ready to receive a job
START JOB - the system has received a job and is
processing it
The following keys are available in START mode:
RESET - immediately aborts router movement and purges the
job
START/STOP - pauses processing the job
Operating Principles 21
START READY
1. While in the STOP READY mode, use the arrow keys to slew
the carriage to the starting location of the job.
2. Press the START/STOP key to display the START READY
message. The AR600 is now in a "ready" state and the
message remains until the data arrives from the GRAPHIX
ADVANTAGE.
CAUTION: In START READY mode, the router carriage may
move without further warning.
The current tool position becomes the start point for the job.
START JOB
When the job data is received from the GRAPHIX ADVANTAGE,
the START JOB message appears, indicating that the machine is
in a "run" state. The GRAPHIX ADVANTAGE sends a header or
tool message, the machine goes into STOP JOB mode, and
instructs the operator to load material. Press START/STOP again
to display the tool assignment. To begin the job, press
START/STOP again.
CAUTION: The router carriage may move without further
warning.
22 ADVANTAGE Router
STOP MODE
STOP mode, as shown by a message in the display panel, may be
in one of two states:
STOP READY - the router is in an "idle" state waiting to
receive data
STOP JOB - the router is in a "pause" state during a job
The following keys are available in STOP mode:
START/STOP
RESET
Z INIT
SELECT
arrow keys
STOP READY
In STOP READY, the GRAPHIX ADVANTAGE sends data to the
ARC Box. The system beeps when data is received and J,j is
displayed in the lower right corner of the message display panel.
Press the START/STOP key to begin the job.
The carriage can be slewed to establish a start position for
the next job.
The job start position can be changed in the STOP READY mode.
It can also be changed when one of the following occurs:
SET HOME is selected from the menu
the job completes
the operator presses RESET to abort the job and clear it from
the ARC Box
the ARC Box receives a terminate command from the
GRAPHIX ADVANTAGE Plot Spooler.
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