Gerber ODYSSEY XP Owner's Manual

Owner’s Guide

COPYRIGHT
COPYRIGHT 2002 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 Gerber ODYSSEY XP Plotter. 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:
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.
Information in this document is subject to change without notice.
PRINTED IN USA
GSP, GERBER EDGE, and GRAPHIX ADVANTAGE are registered trademarks, and Gerber ODYSSEY XP, GA, OMEGA, MacImprint, GERBER MAXX, Automatic Material Alignment, and GerberMag, are trademarks of Gerber Scientific Products, Inc. HPGL is a trademark of Hewlett-Packard Company. Scotchcal is a trademark of 3M Corporation. Windows is a registered trademark of Microsoft Corporation in the US and other countries.
FCC NOTICE
Warning: Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.
Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. 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 expense.
RS-232 shielded cables must be used with this unit to ensure compliance with the Class A FCC limits.
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.

Contents

Chapter 1: Introduction................................................................................................ 1
Features......................................................................................................................................... 1
In this manual ...............................................................................................................................2
Safety............................................................................................................................................ 3
Customer support.......................................................................................................................... 3
Chapter 2: Getting Started........................................................................................... 4
Unpacking and setting up the plotter ............................................................................................4
Connecting the data and power cables.......................................................................................... 4
Turning on the plotter ................................................................................................................... 5
Adding the ODYSSEY XP to the cutting software ......................................................................5
Loading material...........................................................................................................................6
Cutting clear material..................................................................................................................12
Turning off skew control ............................................................................................................ 12
Checking and measuring the available cutting area.................................................................... 14
Installing tools ............................................................................................................................15
Changing knife blades ................................................................................................................ 16
Adjusting knife blade exposure ..................................................................................................17
Chapter 3: Running Jobs.............................................................................................19
Learning the control panel .......................................................................................................... 20
Running jobs............................................................................................................................... 22
Pausing, restarting, and canceling jobs....................................................................................... 25
Automatically cutting off a job................................................................................................... 26
Making jobs fit............................................................................................................................27
Aligning with printed images......................................................................................................28
Chapter 4: Tool Settings............................................................................................. 29
Using the ODYSSEY XP with Gerber software......................................................................... 29
Determining which rule set is used............................................................................................. 30
Choosing the material................................................................................................................. 32
Setting the tool force................................................................................................................... 33
Adjusting corners........................................................................................................................ 36
Setting the speed ......................................................................................................................... 39
Setting acceleration..................................................................................................................... 40
Chapter 5: Advanced Functions................................................................................ 42
Repeats........................................................................................................................................42
Material pulldown....................................................................................................................... 43
Pouncing ..................................................................................................................................... 45
Factory default settings...............................................................................................................48
Communications......................................................................................................................... 51
Chapter 6: Troubleshooting....................................................................................... 54
Version number ..........................................................................................................................54
Warning messages ...................................................................................................................... 55
Error messages............................................................................................................................ 57
Common problems/solutions ...................................................................................................... 62
Chapter 7: Maintenance............................................................................................. 64
Cleaning...................................................................................................................................... 64
Cut strip replacement.................................................................................................................. 69
AC fuse replacement...................................................................................................................70
Chapter 8: HPGL Support ........................................................................................... 71
HPGL command set.................................................................................................................... 71
HPGL test file............................................................................................................................. 73
Changing the HPGL units........................................................................................................... 74
Appendix: Specifications............................................................................................75
Index ............................................................................................................................... 76

Chapter 1: Introduction

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

Features

The ODYSSEY XP plotter has many features that make it easy and convenient to use:
1
Automatic Material Alignment with edge alignment sensors provide
quick and easy loading.
Active Material Edge Tracking Control/Slew Control during jobs
assures long-term, accurate cutting and plotting with minimum supervision.
The ODYSSEY XP draws, cuts, and pounces designs on a variety of
material types and dimensions: Material length from 6" (15.2 cm) to as long as a 50 yd (45 m) roll Material width from 5" (12.7 cm) to 52" (132.1 cm)
Maximum cutting width - 49" (124.5 cm)
Jobs can be controlled entirely from OMEGA or GA version 6.2.1 or
higher. Selecting a specific material automatically sends the appropriate tool settings for that material to the ODYSSEY XP.
Pounce instructions can be sent from OMEGA or GA 6.2 or higher.
The control panel and display provide fast and easy settings
adjustment. Tool settings and other parameters can be made right at the plotter.
CHAPTER 1
2
Introduction
The ODYSSEY XP calculates the job extremities when it receives a job.
If the job will not fit or the starting position must be adjusted, it displays an appropriate message (when used with OMEGA or GA).
Repeats (up to 9999 copies) of the last job plotted can be run from the
ODYSSEY XP.
The operator can suspend a job, move the material for easy viewing,
and resume the job without affecting the material or job.
You can upgrade the plotter firmware by downloading new firmware
from your PC.

In this manual

This manual contains the following sections:
Introduction presents basic information about this manual.
Getting Started tells you how to connect the ODYSSEY XP, use the
control panel and menus, load material, and install tools.
Running Jobs presents the procedures for using the ODYSSEY XP control panel for cutting, plotting, and pouncing single and multiple jobs.
Tool Settings shows how to use either the plotter or Gerber OMEGA or GA software to choose tool settings.
Advanced Functions describes functions beyond routine job cutting.
Troubleshooting provides a list of error messages and possible
solutions.
Maintenance describes routine cleaning and replacement procedures.
HPGL Support presents information about using the HPGL command
set to support the ODYSSEY XP plotter.

Conventions used in this manual

The following conventions are used in this manual:
WARNING: A warning statement contains information which, if not observed, could result in personal injury.
CAUTION: A caution statement contains information which, if not observed, could result in damage to the equipment.
Note: A note contains important information which could affect successful completion of a task.
Tip: A tip is a hint to help you do something more efficiently or quickly.
3
This typestyle
message display or your computer monitor.
A dotted box display.

Safety

WARNING: Unplug the power cord before performing any maintenance. Voltage is present inside the system even after the power switch is turned off. All voltage is removed only when the power cord is unplugged.
CAUTION: Static electricity may damage electronic components. Ground yourself by touching any bare metal inside the plotter frame prior to handling electronic components.

Customer support

If you require assistance, please contact your Gerber distributor or contact the Gerber Field Service Department at:
800-828-5406 (USA and Canada)
860-643-1515 (International) 860-648-8376 (fax)
portrays messages that appear on either the ODYSSEY XP
around
Start-Job
is used to indicate a blinking
e-mail: gsptech@gspinc.com
www.gspinc.com
CHAPTER 2
4
Getting Started

Chapter 2: Getting Started

This chapter contains the steps you need to prepare the plotter for cutting:
unpacking and setting up the plotter
connecting the data and power cables
turning on the plotter
adding the ODYSSEY XP to the cutting software
loading material
installing tools
changing knife blades
adjusting knife blade exposure
Unpacking and setting up the plotter
The ODYSSEY XP is shipped from the factory in reusable packaging materials. Included with the plotter is the booklet ODYSSEY XP unpacking, assembling, and repacking instructions. Follow these instructions to unpack the plotter, assemble the stand, and mount the plotter on the stand. Save the packaging materials and instructions in case you need to ship the plotter in the future.
Connecting the data and power cables
The ODYSSEY XP is supplied with a serial cable and power cord. They plug into the plotter at the left rear corner (when you are facing the front).
To connect the data and power cables
1 Connect the 25-pin connector end of the serial cable to the connector
on the plotter and tighten the screws.
2 Connect the other end of the serial cable (9-pin connector) to a COM
port on your computer.
3 Connect the receptacle end of the power cord to the plotter. Do not
plug the power cord into the wall receptacle at this time.

Turning on the plotter

When you turn on power, the plotter performs a check and initialization sequence. The carriage taps the right stop, then moves approximately 2" (5 cm) to the left. When these steps are completed, the Main Menu appears.
To turn on the plotter
1 Close and latch the tool holder as shown below.
5
2 Plug in the plotter power cord to a wall receptacle.
3 Turn on the power switch located on the front left side of the plotter.
The plotter completes the start-up sequence, then the Main Menu appears in the control panel display.
MAIN MENU
Settings Mode: Single Menu 1 Job Status: No Job

Adding the ODYSSEY XP to the cutting software

After physically connecting the ODYSSEY XP to the computer, you have to add the ODYSSEY XP to the list of available plotters in the software. The addition makes the plotter available for cutting. If you are an OMEGA or GA user, follow the instructions in the Reference manual to add the ODYSSEY XP as the default plotter. If you are using non-Gerber
CHAPTER 2
6
Getting Started
software, refer to the software manual for instructions for adding the plotter in that software.

Loading material

The ODYSSEY XP cuts and plots a wide variety of vinyl film, masks, and papers. Always use Gerber-authorized materials for highest quality.
CAUTION: Do not load the material with a tool installed in the tool holder. Loading material into the plotter with the tool installed can result in damage to the blade or the material.
CAUTION: Check the material edge for irregularities that could cause tracking problems. If the material has an irregularity bigger than a sprocket hole on punched material, turn skew off. (See page 12.)
Tip: To prevent material edge irregularities, always store material horizontally or vertically on the left edge.
Material loading consists of three steps:
mounting the roll on the plotter
loading the material into the plotter
verifying the material alignment
In addition, you may need to:
cut clear material
turn off skew control
check and measure the available cutting area

Mounting the roll on the plotter

There are three material roll stops that should be installed on one of the two material rollers (instructions for installing them are in the ODYSSEY XP unpacking, assembling, and repacking instructions). The right edge of the one on the left (as you face the plotter from the rear) should be aligned with the alignment mark on the plotter platen. The center stop should be moved against the right edge of the material roll to prevent the roll from “walking” during cutting. The right stop should be pushed against the right material roller support and tightened so that it can act as a friction brake on the roller. The material rollers are installed on the brackets behind the plotter (as shown below).
Left stop (aligned with mark on platen)
Note : Dampener bar not shown in this view.
To mount the material roll on the plotter
Center stop
7
Right stop pushed against material roller support. Note the white stop set screw.
1 Slide the material roller with the stops to the left as you slide the right
stop to the right so that the right stop puts a light pressure on the material roller support, then tighten the white stop set screw. (You may need to periodically readjust this stop as it wears. If the plotter seems to be putting too much force on the material during pulldown, readjust the stop to loosen the pressure on the material roller support.)
2 Verify that the right edge of the left roll stop is aligned with the
alignment mark on the platen, then tighten the stop set screw. You should not have to reposition this stop unless the material is not aligned with the alignment mark on the platen.
3 Put the roll on the material rollers between the left and center stops
and with the free end of the material toward you.
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8
Getting Started
4 Push the center stop against the right edge of the material roll, then
tighten the stop set screw. (If you change the size of the material, you will need to change the position of this stop.)

Loading the material into the plotter

The material is driven through the plotter by the grit wheels (located in the platen) when it is trapped between the pinch and grit wheels. Therefore, the location and alignment of these wheels is important when loading material.
The figures show the position of the material with respect to the pinch and grit wheels. When material is loaded correctly, the material edge will extend past the center of both grit wheels by 1/2" (1.3 cm).
Material extends 1/2" past center of adjustable grit wheel.
Wrong
Material inside pinch wheels
Pinch Wheels
Material
Grit wheels
1/2“ min.
Correct
Material safely outside pinch wheels
Material does not extend to end of grit wheels.
Material extends 1/2" past center of fixed grit wheel.
To help you locate and align the grit and pinch wheels, there is a measuring scale on the platen. Use the lower scale inch readings for material up to 25" wide. Use the upper scale inch readings for material more than 25" (64 cm) wide. When you slide the material width adjustment handle to set the grit wheels for the material width, both the left and center grit wheels move as a unit. When you slide the pinch wheels, both the left and center pinch wheels move as a unit.
CAUTION: Raise the pinch wheels off the grit wheels (push the pinch wheel lever toward the back) when the ODYSSEY XP is not in use. This prevents creating flat spots on the wheels.
Pinch wheel lever
9
Right pinch and grit wheel
Pinch wheels with grit wheels underneath
Material (width) sensors
Measuring scale
To load material into the plotter
Tip: Use the left and right slew keys on the control panel to move the carriage near the center to make loading material easier. For information on using the slew keys, refer to “Learning the control panel” on page 20.
1 Raise the pinch wheels off the grit wheels by pushing the pinch wheel
lever toward the back.
Alignment mark
Edge sensor and deflector
CHAPTER 2
10
Getting Started
2 Push in and slide the material width adjustment handle to set the grit
wheels for the material width. If you set the width to the actual material width, the scale provides a compensation so that the material properly extends 1/2" (1.3 cm) beyond the center of the left grit wheel. If necessary, slide the material over the platen and use it to measure that the material extends properly beyond the center of the left grit wheel.
3 Slide the pinch wheels directly above the grit wheels.
4 Set the controls on the middle pinch wheel as follows:
If you are loading paper or drafting vellum, and it is wider than 25"
(64 cm), pivot the riser block up to prevent the center pinch wheel from contacting the material.
If you are loading narrow material (less than 25" (64 cm)), pivot the
Hi-Lo Force lever on the center pinch wheel assembly up. If you are loading material wider than 25" (64 cm), pivot the Hi-Lo Force lever down. Verify that the lever is in the correct position by looking at the message display on the control panel.
Force lever in down position
Riser block in up position
5 Slide the material over the platen and under the pinch wheels.
6 From the front of the plotter, slide the material to the right so that the
right edge of the material is exactly aligned with the alignment mark on the platen and the leading edge of the material is beyond the front edge sensor. Make sure the material runs under both the front and rear edge sensors and deflectors.
11
7 Pull the pinch wheel lever toward the front to clamp the material
between the grit and pinch wheels.
8 The control panel displays the following:
SELECT MATERIAL TYPE
Sheet Roll
Press F1 or F3
9 Press either F1 (sheet) or F3 (roll) to select the material type. For
information on using the F1, F2, F3, and F4 function keys, refer to “Learning the control panel” on page 20.
Note: After pulldown (See page 43), the Odyssey XP will return the material to the starting position. Do not rewind the surplus material. Allow it to drape over the dampener bar which promotes a smooth material feed to the cutting tool.
Dampener bar
Material path before pulldown Material path after pulldown

Verifying the material alignment

After you load the material, run auto alignment. The time to perform this process varies with the amount of error detected.
To perform the material alignment sequence
1 When the display shows
2 The display shows
pinch wheels.
3 The display changes to
material is moved back and forth as the edge is aligned.
4 When the material is properly aligned, the Main Menu appears.
Locating Pinch Wheels
Auto Align Material?
, press F3 (Yes).
while the carriage locates the
Material Auto Align in Progress
while the
CHAPTER 2
12
Getting Started
5 If an error is detected, the display shows
indicate improper loading
To check and reload material
1 Make sure the material roll stops are in the correct position and that
the roll hasn’t “walked” during the material alignment sequence.
2 Remove and reload the material.
3 Make sure the material runs under both the front and rear edge
sensors.
4 Make sure the grit wheels, pinch wheels, and pinch wheel lever are in
the correct position.
5 If the right edge of the material is damaged, or if the sheet is small
(typically shorter than 25" (64 cm)), select No for and turn skew control off as described later in this section.

Cutting clear material

Clear (transparent) material (such as Clear Enamel Receptive, or any material with a clear edge) is not detected by the optical edge sensors. Auto alignment, skew, and material out indications are not in effect because the material is invisible to the optical edge sensors. When using clear material, the following special instructions apply.
Reload Material. Sensors
.
Auto Align Material?
To use clear material
1 Load and manually align the material to make sure it is straight.
2 Pull the pinch wheel lever forward. The message
appears.
3 Press F4 (Ignore).
4 Press F3 (Search) to locate the pinch wheels.
5 Run the job.
Note: Not all “clear” materials go undetected at first. If you are having difficulty with a material you believe to be “clear,” turn off skew control as described in the next paragraph.

Turning off skew control

Skew control maintains material edge alignment during operation. The two material edge sensors monitor material edge movement to eliminate
No Material Found
13
drift. When running some materials, it is recommended that skew control be turned off. In most of these cases, the plotter will not see the material at all, and will automatically run with skew off. To avoid any instances were skew might be turned on or off during running of these materials, it is suggested that skew control be turned off before loading the material and the auto-align feature not be used. Align the material by hand/eye using the guide marks on the plotter extrusions near the edge sensor. If the plotter asks to auto-align the material, press the Function key F1 for "No".
Note: Normally, skew control is ON. If you are running scrap material, transparent materials, or material with an uneven edge, turn skew control off.
Turn skew off if runnng the following materials:
225 Clear Enamel Receptive (without the black edge stripe)
GerberVision
Gerber Sandblast Stencil #521 and #522 (edge-stripped and on clear liner)
Imagecast Eclipse
LexEdge Clear
LexEdge II
LexEdge II Polished/Clear
Dusted Crystal
Frosted Crystal
Gerber 20-pound Paper
Any non-Gerber clear material with clear backing
Any non-Gerber paper 20-pound or less
Gerber does not recommend using the ODYSSEY XP to cut screenprint films such as Rubylith.
When you return to using other material, make sure you turn skew control back on (normal or short).
To turn skew control off
1 At the Main Menu, press F4 (Menu 1).
2 At the Menu 1 display, press Skew (F4).
3 The skew display appears and shows that skew is ON - norm. Press
either F3 or F4 to step through the choices (ON − norm, ON − short for material less than 48" (122 cm) wide, or OFF).
CHAPTER 2
,
14
Getting Started
SKEW Skew Control: + ON −−− norm
ENTER Key to Accept
-
F3
F4
4 Press Enter twice to return to the Main Menu.

Checking and measuring the available cutting area

After you load material, you can check and measure available cutting area dimensions. After you load material, the plotter checks the width available for cutting. For sheet material, it also checks the length. This feature lets you plan and lay out jobs to make efficient use of material.
To check a cut area
1 At the Main Menu, press F4 (Menu 1).
2 Press F1 to check the cut area. The display shows the dimensions of
the job, which is slightly less than the material dimensions. If roll material is used, the length appears as 0.
Material Cut Area
Length: Width:
42.00 in 35.50 in (107.52 cm 90.17 cm )
To measure a cut area
1 At the Main Menu, press F4 (Menu 1).
2 Press F2 to measure an area.
3 Use the left and right slew keys on the control panel to slew the
carriage to the point where you want to begin.
4 Press F4 to reset the display to zero.
Length: Width:
0.00 in 0.00 in (0.00 cm 0.00 cm )
Slew
ENTER, F4 = Reset
5 Use the left and right slew keys to move the carriage.
distance the tool moved from the zero set point. Use the up and down slew keys to move the material. moved from the zero set point.

Installing tools

The knife, pen, and optional pounce tools are all installed into the tool holder the same way. This paragraph provides information on installing a tool. For information on changing and adjusting blades, see Chapter 4, “Tools and Tool Settings”.
If you are using a Gerber target alignment tool to align the tool holder with printed registration marks on the material, refer to “Aligning with printed images“ on page 28.
To install a tool
1 Move the carriage to the middle of the plotter by pressing the left or
right slew key.
Width
Length
shows the distance the material
15
shows the
Tool holder
Latch fastener
2 Open the tool by turning the latch fastener counterclockwise and
gently pulling the holder open.
3 Place the tool into the tool holder, making sure that the tool flange fits
into the groove.
CHAPTER 2
16
Getting Started
Groove
Flange
4 Close the holder and secure it by turning the latch fastener clockwise.

Changing knife blades

Knife blades dull slightly over time. Blade wear is normal and always a gradual change. Adjusting tool settings, as described in Chapter 4, Tools and Tool Settings, can extend blade life.
Blades are ground to a controlled length and cannot be resharpened. A sudden decline in cutting quality could indicate that the blade was chipped or damaged. Replace and discard any chipped blade.
In addition, you may need to change a knife blade if you use different materials. The following chart summarizes knife blade angles and material used.
Blade angle Examples of material used with specific blades
30° Thin materials, such as Ulano and Autotype 45° 60° Thick materials, such as Sandblast and
WARNING: Handle the blades carefully. Blades are extremely sharp. They are brittle and can easily chip.
To change the blade
1 Hold the knife tool so the blade points
toward the ceiling.
2 Remove the adjustment cap by turning it
counterclockwise until it comes off completely.
3 Remove the old blade by pulling it straight
out with a pair of tweezers.
4 Use tweezers to put in the new blade. Be
careful not to touch the cutting edge with the tweezers.
5 Press the blade tip lightly with the flat of
your fingernail to ensure it is all the way into the blade holder.
6 Put the adjustment cap back on carefully
and turn it clockwise.
Most materials, such as Scotchcal 220
GerberMag
Knife Tool
Adjustment Cap
Blade
Blade Holder
17
7 Adjust the blade by following the
directions in the next paragraph, “Adjusting knife blade exposure.”

Adjusting knife blade exposure

Cut quality is directly related to the correct blade exposure for the material being cut. Too little blade exposure can make weeding difficult. Too much blade exposure combined with too much force can cut through the material backing and decrease cut quality.
CHAPTER 2
18
Getting Started
The blade holder has hash marks around it. The adjustment cap has a pointer, which lines up with the hash marks. One hash mark equals
0.001" (1 mil or 0.0254 mm).
Tip: The autocut off feature might require more blade exposure than normal.
To set the blade exposure
1 Hold the knife tool with the blade toward the ceiling. The blade
should extend beyond the end of the adjustment cap by approximately the thickness of two sheets of paper. (This is the correct setting for Scotchcal 220 material. Other materials require different exposure.)
2 To extend the blade, turn the adjustment cap clockwise. To retract the
blade, turn the adjustment cap counter clockwise.
CAUTION: When performing the next step, do not press too hard on the material. Too much pressure can damage the blade.
3 Place a piece of the material you will be cutting on a flat surface and,
pressing gently, scribe a circle with the tool by hand.
4 Weed the circle. If it weeds properly without cutting into the backing,
the blade exposure is correctly set for that material.
5 If the material has not been cut all the way through, turn the
adjustment cap clockwise one or two hash marks to expose more blade. Go back to Step 3. Repeat the procedure until the scribed circle weeds properly without cutting the backing material.
6 If the backing material has been cut, turn the adjustment cap counter
clockwise to decrease the blade exposure. Go back to Step 3. Repeat the procedure until the backing material is no longer cut and the scribed circle weeds properly.

Chapter 3: Running Jobs

This chapter describes the control panel and its use and explains how to run jobs :
learning the control panel
running jobs
pausing, restarting, and canceling jobs
automatically cutting a job off the roll
making jobs fit
cutting graphics printed on the EDGE, EDGE 2, and MAXX
19
CHAPTER 3
20
Running Jobs

Learning the control panel

The plotter control panel provides functional control and status displays.
The control panel consists of:
the message display
four menu selection function keys (F1, F2, F3, F4)
two control keys (ENTER and CANCEL)
four slew keys
Note: For an outline of the menu structure, please refer to the reference card included with this manual.
F1
F2
Menu item
Menu item
ENTER
TITLE
Instruction s
Menu item
Menu item
CANCEL
F3
F4
The message display shows menus, instructions, system and job status, and messages. Each menu has a title (for example, MAIN MENU). To step through menus, press the function keys.
The F1, F2, F3, and F4 function keys select other menus and change parameter values or settings. Their function is based on the text in the display associated with each function key.
In the settings menu, the ENTER key saves settings. From a submenu, it returns to the MAIN MENU.
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