Zund M-1600, L-3200, L-2500, XL-3200, 2XL-1600 Operating Manual

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Digital flatbed cutter G3 series

(M-1600, M-2500, L-2500, L-3200, XL-1600, XL-3200, 2XL-1600, 2XL-3200, 3XL-1600, 3XL-3200)

Operating manual

Original operating instructions

Author Technical Communications

Department, Zünd Systemtechnik AG

Composition and publication Zünd Systemtechnik AG

Version:

Menu version:

Date:

Doc. no.:

Zünd Systemtechnik AG

1.45

05-2010

5106015

G3 series

Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Using the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.1 Structure of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Points to note when reading this operating manual . . . . . . . . . . . . . . . . . . 4

1.4 Care of the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.5 Current status of documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6 Standardisation, tests, marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6.2 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6.3 UL testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.7 Legal notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.8 Troubleshooting, hints and tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.9 Documented cutter models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.10 Publishing details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.2 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2.1 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2.2 UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 Cutter - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.5 Modules, tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.5.2 UM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.5.2.1

2.5.3 RM-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.5.4 PUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.5.5 MAM-S/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.6 Material handling, options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6.1 Laser pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6.2 ICC camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6.3 Cutter with static work surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6.4 Cutter with conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.6.5 Sheet feeder options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.6.6 Drip tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.7 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7.1 Complete machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7.2 Schedule of work sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7.3 Complete machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.7.4 Movement system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.7.5 Processing materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.8 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.8.1 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.8.1.1

2.8.1.2

2.8.2 Electrical connection, power consumption . . . . . . . . . . . . . . . . . . . . . . . . 19

Tools for the UM

Basic device

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Cutter extension

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2.8.3 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.8.4 Basic device compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.8.5 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.8.6 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.8.7 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.8.8 FCC approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.3 Examples of improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.4 Hazard warnings, important instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.4.1 Explanation of the hazard warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.4.2 Structure of the hazard warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.5 Areas of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.6 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.7 Rules and safety at work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.8 Procedure in case of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.9 Danger areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.9.1 General danger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.9.2 Danger area on the module carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.9.3 Danger area during the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.10 Working and traffic area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.11 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.11.1 Responsibility of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.11.2 Position of the safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.12 Safety and monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.12.1 Protective system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.12.2 Operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.12.3 Emergency stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.12.4 Safety cut-off feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.13 Personal protective equipment, clothing . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.14 Mechanical hazards . . . . . . . . . . . . . . . . . . . . . .

3.14.1 Gathering, retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.14.2 Gathering, impacts of foreign objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.14.3 Cuts and stab wounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.15 Risk of burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.16 Electrical hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.17 Risks arising from the emission of toxic dust . . . . . . . . . . . . . . . . . . . . . . 21

3.18 Risks arising from the processing of toxic/hazardous materials . . . . . . . . 21

3.19 Environmental hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.20 Handling and storage of chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.21 Risk of fire and explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.22 Danger caused by laser beam (laser pointer) . . . . . . . . . . . . . . . . . . . . . . 25

3.23 Safety instructions for operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.24 Safety precautions for service personnel . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.25 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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4 Controls and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.2 Safe working practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.3 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4.3.1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4.3.1.1

4.3.1.2

4.3.1.3

4.3.1.4

4.3.1.5

4.3.1.6

4.3.1.7

4.3.2 Emergency stop switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.3.3 Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.3.4 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.4 Menu navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.4.1 Menus and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.4.2 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.4.3 Info menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.4.4 Popups/dialogues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.4.5 User level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4.6 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.5 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5.1 Set language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5.2 Set display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5.3 Setting the volume of the signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5.4 Delete data buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.6.1 Daily checks prior to start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.6.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.6.3 Operating status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.6.3.1

4.6.3.2

4.6.3.3

4.6.4 Moving the bar/module manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.7 Handling modules/tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.7.1 Module/tool/tool insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.7.2 Set module/tool change position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.7.3 Inserting/replacing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.7.3.1

4.7.3.2

4.7.4 Activating a module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.7.5 Tool handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.7.5.1

4.7.5.2

4.7.5.3

4.7.6 Attaching/selecting a tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.7.6.1

4.7.6.2

4.7.6.3

Operating unit Navigation keys Numerical keys Function keys Travel keys Soft keys Special keys, shortcuts

OFFLINE STOPPED ONLINE

Module mount Inserting/replacing the module (e.g. UM)

Marking the tool (e.g.) Switching the tool manager on/off

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Tool manager — change tool (UM module)

Creating a new tool Selecting a tool Deleting a tool

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4.7.6.4

4.7.7 Inserting and connecting a tool (e.g. oscillating tool) . . . . . . . . . . . . . . . . 33

4.7.8 Connecting driven tools - allocating port . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.7.8.1

4.7.8.2

4.7.9 Tool positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.8 Material hold-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.8.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.8.2 Defining/checking the vacuum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.8.3 Setting the strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.8.4 Switching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.8.5 Working with air-permeable materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.9 Feeding options* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.9.1 Feeding clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.9.2 Feed guide rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.9.3 Feeding options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.9.3.1

4.9.3.2

4.10 Automatic tool initialisation (AKI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.10.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.10.2 Adjusting the height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.10.3 Initialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.11 Laser pointer, reference point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.11.1 Laser pointer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.11.2 Reference point settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.11.3 Choose laser pointer as pointer type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.11.4 Define reference point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.12 Material stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.13 Module carriage slot protective plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.14 Module and tool holder* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.15 Switch off the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Saving tool-specific cutter settings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Connection - electrical tools (EOT, DRT, etc.) Connection - pneumatic tools

Automatic feed Manual feed

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . . . . . . 35

5 Description of menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5.2 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5.3 Description of menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6.2 Locate error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6.2.1 Error display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6.2.2 Error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6.3 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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7 Cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7.2 Safe maintenance of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7.3 Operating resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7.3.1 Handling operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7.3.2 Cleaning fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7.3.3 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7.3.4 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7.4 Steps for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.5 Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7.6 Accessories case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7.7 Maintenance jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7.7.1 Service flaps and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7.7.2 Maintenance position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.7.3 Visually inspect the machine for damage . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.7.4 Clean the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7.7.5 Clean X axis guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.7.6 Oil X axis guide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7.7.7 Cleaning/oiling Y axis guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7.7.8 Lubricating the Y axis bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.7.9 Clean the chipping protection brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.7.10 Cleaning the feeding clamps/feed guide rail . . . . . . . . . . . . . . . . . . . . . . . 23

7.7.11 Draining the maintenance unit condensation water . . . . . . . . . . . . . . . . . 24

7.7.12 Automatic circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.7.13 Conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

7.7.13.1

7.7.13.2

7.7.13.3

7.8 Instructions for disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.9 Starting up after periods at a standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.9.1 Vacuum generator 1-9 KW/1-15 KW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Removing the conveyor belt Removing the covers Fitting a conveyor belt

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 Material handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12 Additional specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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G3 series Introduction

Foreword

1 Introduction

Zünd Systemtechnik AG Altstätten, Switzerland

1.1 Foreword

Dear customer,

By purchasing our product you are participating in the worldwide success of Zünd cutter systems.

The modular design of our systems ensures:

• A system solution that is suited to your individual requirements in terms of speed and quality

• The availability of the most up-to-date technology thanks to constant developments

Our approach

Constant and intensive cooperation with successful users is a prerequisite for innovative and practical solutions. We are therefore grateful for any comments or suggestions on how we can improve.

Contact

Zünd Systemtechnik AG Industriestrasse 8 CH - 9450 Altstätten

Tel. ++41 71-757 8181

Fax ++41 71-757 8191

www zund.com

info@zund.com

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Introduction G3 series

Using the documentation

1.2 Using the documentation

The instruction handbook supplied is intended to help you to:

– Operate the machine safely

– Perform routine machine maintenance

– Use the machine optimally in all permitted areas

To do this, you need to be able to find what you want within the documentation.

The instruction handbook comprises:

Volume 1 - Operating manual

This volume contains information on the engineering, installation, operation and maintenance of the basic machine.

The technical documentation for the service personnel is contained in volumes 2 and 3:

Volume 2 - Service manual *

This volume contains information on the structure of the machine and on servicing by authorised service personnel

Volume 3 - Spare parts catalogue * (See Zünd homepage)

1.2.1 Structure of the operating manual

The operating manual consists of individual, consecutively numbered chapters. These sections are arranged according to the ring binder tabs.

The table of contents provides information on the structure of the individual chapters.

The numbers of pages and certain large graphics are prefixed with the number of the relevant chapter. Page number "2-10", for example, means the tenth page of chapter 2 "Product description".

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G3 series Introduction

Using the documentation

1.2.2 Symbols

Illustration

Close, fix, tighten, in

Open, release, loosen, out

Higher

Lower

Text structuring

Task: Steps to perform

Result: Outcome of the tasks performed.

Prerequisites for performing a task

List of tools

Optional accessories

There are a number of optional accessories available for the machine. Any description relating to an optional accessory is identified in the operating manual by the * symbol.

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Introduction G3 series

Points to note when reading this operating manual

1.3 Points to note when reading this operating manual

Text references

Chapter headings are numbered consecutively, with the first figure corresponding to the chapter number. Where reference is made to sections outside the current chapter, note the first figure and turn to the corresponding chapter, which contains the cited section. See chapter 2-4 "Overview of the machine", for example, leads to chapter 2 "Product description", which contains section 4 "Overview of the machine".

Sketches and schematic representations

These are provided for general information and do not necessarily correspond to the latest version of the machine.

Dimensional information

Dimensional information is listed in the SI/US unit system according to the place of installation.

1.4 Care of the documentation

Volume 1 "Instruction manual" must always be kept in close vicinity of the workstation.

Volume 2 "Service manual" must be made available to maintenance and service personnel when required.

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G3 series Introduction

Current status of documentation

1.5 Current status of documentation

Act accordingly to make sure that the documentation is complete and up-to-date at all times:

– Do not remove parts of the documentation

– Request copies of missing or illegible pages from the manufacturer, or download

and print them from the Zünd homepage

– If any new documentation is delivered as a result of conversions taking place, file

it away immediately

– If documentation is changed, file the new information and destroy the old

– If the documentation exists in more than one language, ensure that all languages

are kept up-to-date

1.6 Standardisation, tests, marking

1.6.1 Standards

Scope of the documentation supplied

Volume 1: Operating manual

Volume 2: Service manual *

Volume 3: Spare parts catalogue *

Execution

This operating manual makes reference to the following standards:

• EN 62079

• EN 62023

• ANSI Z535-6

• EN ISO 12100-2

Important!

EU standards and guidelines which are applied are listed in the declaration of conformity.

In the interests of our customers, we reserve the right to make changes as a result of technical improvements. This document therefore corresponds to the technical status of the product supplied and not the manufacturer's current state of development.

1.6.2 CE marking

Within the EU, the cutter system is delivered with CE marking and an EC declaration of conformity according to Annex II A of the EC Machinery Directive 2006/42/EC (see chapter "Documents")

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Important!

If the purchaser adds additional devices to the cutter system, or if the system is integrated into an larger system then the device is supplied with a "Declaration for the installation of an incomplete machine" according to Appendix II A of the EU

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Introduction G3 series

Standardisation, tests, marking

Machinery Directive 2006/42/EC and/or without CE marking. As a result, the declaration of conformity must be issued again by the purchaser.

1.6.3 UL testing

Zünd G3 cutters have been UL tested and comply with the ISO 60950 standard.

The certification can be accessed under UL number E176661.

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G3 series Introduction

Legal notice

1.7 Legal notice

The information contained in this publication is intended for information purposes only and is subject to change without notice at any time. This does not constitute an obligation on the part of Zünd Systemtechnik AG.

No part of this document may be copied, distributed, used or disclosed to third parties without express permission. Offenders will be liable for damages.

1.8 Troubleshooting, hints and tips

Important!

You can find information about troubleshooting and useful hints and tips on the Zünd homepage. (www.zund.com)

1.9 Documented cutter models

This documentation applies for the following types of G3 series cutters.

G3 series

M line L line XL line 2XL line 3XL line

M-1600 L-3200 XL-3200 2XL-3200 3XL-3200

M-2500 L-2500

1.10 Publishing details

Name

Operating manual for G3 series cutters, side-support version.

Composition, illustration and publication

Zünd Systemtechnik AG - Technical Communications Department

©Copyright

Zünd Systemtechnik AG

XL-1600 2XL-1600 3XL-1600

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Publishing details

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G3 series Product description

General

2 Product description

2.1 General

This chapter contains information on the following:

– Representational conventions in the operating manual

– Possible uses of the machine

– Structure of the main components

– Important technical data

– General technical description of the device

Directional information

Directions such as "right, left" or "forwards, backwards" are specified according to the operator's view of the machine during operation.

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Fig. 2-1 Directional information

1 Front 3 Left

2 Back 4 Right

Y Y axis X X axis

Important information

Important!

Refers to user tips and useful information which enhance the usability and prolong the service life of the machine and make the work significantly easier.

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Product description G3 series

Product identification

2.2 Product identification

2.2.1 Rating plate

Important!

The rating plate is used to uniquely identify your machine.

Fig. 2-2 Position of rating plate

1 Manufacturer

2 Product category

3 Device type

4 Serial number

see chapter "Introduction", "Standardisation, CE marking"

Structure of the serial number

Example:

Serial number Description

G3 Product

00L Bar length

25 Table length

0001 Consecutive device number

5 Year of manufacture

6 CE marking

7 Manufacturer's address

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G3 series Product description

Intended use

2.2.2 UL marking

Fig. 2-3 UL marking

1 UL marking (Canada, USA)

2 Voltage range

2.3 Intended use

The cutter system can be used for the following purposes:

– As an output device for CAD/CAM data

– For processing and labelling materials arranged on the table

Aside from this, the intended use and the limits of the application are as follows:

– Depending on the tools and material feed system available,

– Described in the chapters "Tools", "Modules" and "Material transport".

3 Max. current

4 Frequency

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Product description G3 series

Cutter - overview

2.4 Cutter - overview

2-4

Fig. 2-4 Cutter - overview

1 Work station

2 Cutter extension, front

3 Table with vacuum

4 Left-hand safety device

5 Bar

6 Cutter extension, rear

7 Boom for router option

8 Power unit

9 Right-hand safety device

10 Electronics unit

11 Vacuum generator

12 Extractor (optional)

13 Maintenance unit (air pressure setting)

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G3 series Product description

Modules, tools

2.5 Modules, tools

2.5.1 General

Modules

The use of modules and tool inserts means that Zünd cutters can be highly specialised on the one hand, whilst still being able to be easily converted for processing other materials on the other hand.

As standard three modules can be fastened onto the module carriage.

Instructions on the operation of your module can be found in the chapter "Modules"/"Tool inserts".

Tools

Zünd offers tools for processing the most wide ranging materials. A selection of important tool inserts can be found under the corresponding module.

On the Zünd homepage (www.zund.com) you can find

Fig. 2-5 Modules - tool inserts - tools

1 1 Modules (UM/RM/PUM) 2 2 Tools (EOT/POT/DRT) 3 3 Module carriage 4 4 Router, blade, etc.

all the current tool inserts or contact your Zünd partner for detailed information.

Instructions on the operation of your tool/module can be found in the chapter "Modules"/"Tools".

2.5.2 UM

Tangentially controlled high-performance module for the following tool inserts:

•POT

•EOT

• DRT

• Various insert sleeves and tool holders

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Product description G3 series

Modules, tools

2.5.2.1 Tools for the UM

POT: Pneumatic oscillating tool for thick or tough materials such as foam, filling materials, thick leather, upholstery fabrics etc.

EOT: Electrical oscillating tool for cutting soft to average toughness materials.

DRT: Driven tool for rotating knives for cutting textiles, fibrous materials such as Kevlar, carbon

VCT: Cutting tool for producing V-cuts

UCT: Cutting tool which can be used universally

KCT: Cutting tool for foils with and without mount material

UDT: Drawing tool

PPT: Passepartout (all-purpose) tool

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G3 series Product description

Modules, tools

2.5.3 RM-A

Router module for the use of 1000 W Zünd motor spindles.

2.5.4 PUM

Motor spindle with 1000 W for the processing of the most wide-ranging materials.

Punching and stamping module for the processing of leather materials.

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Product description G3 series

Modules, tools

2.5.5 MAM-S/D

Single/double marking module for use of ballpoint pens and other marking inserts.

2-8

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G3 series Product description

Material handling, options

2.6 Material handling, options

2.6.1 Laser pointer

The laser pointer is used as an aid for the precise definition of the reference point

2.6.2 ICC camera

The ICC camera is used as an aid for importing the registration marks. The processing of the data is dependent on the communication software.

2.6.3 Cutter with static work surface

The feeding and removal of the processing material takes place on the work surface of the cutter. The work surface is protected against damage using a cutting base.

Fig. 2-6 Static work surface

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Product description G3 series

Material handling, options

2.6.4 Cutter with conveyor

Conveyor systems are used for pulling the materials to be worked with. The conveyor belt is used as a cutting base and conveyor belt at the same time.

During the processing, the material to be processed is fixed in place using a vacuum. After cutting, the bar moves backwards. The conveyor clamping elements fix the conveyor belt and the feeding clamps are pressed onto the material to be pushed forward. The bar tightens the conveyor belt to the set position.

The shape of the feeding clamps varies depending on the material to be worked with. An auxiliary drive is used in the case of larger tables or processing

Fig. 2-7 Conveyor

materials that are heavier for transportation.

Cutter extensions guarantee efficient work. The material supply/removal is carried out while the cutter is completing its jobs. These extensions are available in different sizes, either with or without auxiliary drive.

Fig. 2-8 Cutter extension

2.6.5 Sheet feeder options

Fully-automatic sheet feeding

2-10

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G3 series Product description

Material handling, options

2.6.6 Drip tray

Catches cutting waste

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Product description G3 series

Technical description

2.7 Technical description

2.7.1 Complete machine

The G3 cutter is a variable processing system for flexible and rigid materials with various tool systems. Extension options are available to provide improved handling and for the adjustment of the system to special requirements or for processing specific materials.

2.7.2 Schedule of work sequences

Starting point: CAD/CAM data

Communication software (e.g. ZCC)

Sending the HP-GL data to the cutter

Processing the sent data

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G3 series Product description

Technical description

2.7.3 Complete machine

Table/vacuum plate

The work surface is designed as a perforated sheet. Vacuum zones are arranged under this perforated sheet which are connected to a high-performance vacuum generator via a distributor.

The vacuum is used for holding down and tightening the material to be processed. The cutter control permits sequential activation/deactivation of the individual vacuum zones and therefore reduces energy consumption. The vacuum generator (turbine vacuum generator, vacuum pump) automatically regulates the vacuum strength (100 mBar).

Electronics unit

The electronics unit is housed in the front right-hand side of the cutter and is only accessible for service personnel via a removable cover. The cutter control is housed in the electronics unit.

Power unit

The power unit is housed in the rear right-hand side of the cutter and is only accessible for service personnel via a removable cover. The power unit contains the power supply of the complete cutter and is activated/deactivated using an on/off switch. The connection of the individual consumers takes place using software control if required.

Pneumatics

Air pressure and air flow are adjusted for the respective consumer via a maintenance unit. The maintenance unit is accessible via a service door so that settings and maintenance work can be carried out.

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Product description G3 series

Technical description

2.7.4 Movement system

The G3 series has four electronically driven axes.

Axis Function Movement system

Bar Drive via toothed belt/steel belt

Material transport, material transport extension

Y Movement of the module

carriage

Z Height adjustment of the

module

T Rotary movement of the

module

X axis - bar

The bar is driven by a motor via a toothed belt/gear mechanism and a toothed belt/ metal belt combination. The construction ensures that the function is backlash-free and it also minimises wear on the drive system. The bar is supplied with control signals and compressed air via an energy chain. All drive parts are protected against direct access/contamination using covers.

Feed clamp elements, feeding clamps, auxiliary drive

Drive via toothed belt/steel belt

Example: Universal module, routing module

Example: Universal module

X axis - material transport

The material transport takes place via conveyor clamp elements and feed elements on the bar, which move the conveyor belt including the material to be used via the bar movement. In the case of large cutters, or cutters with material transport extension, an auxiliary drive is also used.

Y axis - module carriage

The module carriage is driven by a motor via a toothed belt/gear mechanism and a metal belt. The construction ensures that the function is backlash-free and it also minimises wear on the drive system. The module carriage is supplied with control signals and compressed air via an energy chain. All drive parts are protected against direct access/contamination using covers.

Z axis - height adjustment of the module

Machine-controlled setting of the processing height (e.g. universal module)

T axis - rotary movement of the module

Modules with integrated T axis (e.g. universal module)

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G3 series Product description

Technical description

2.7.5 Processing materials

The multitude of materials which can be processed with the different module and tool systems means that there is no single way to achieve the target.

However, the following factors always play an important role and must always be set/ selected for the specific material:

• Selection of the module and the tool insert

• Selection of the knife/router

• Descending speed, descending acceleration

• Cutting speed, acceleration

Contact your Zünd partner or the Zünd customer information centre for more precise information.

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Product description G3 series

Technical information

2.8 Technical information

2.8.1 Dimensions and weights

2.8.1.1 Basic device

Type Work surface

(D x E) [mm]

M-1600

M-2500

L-2500

L-3200

XL-1600

XL-3200

2XL-1600

2XL-3200

3XL-1600

3XL-3200

1330 x 1600

1330 x 2500

1800 x 2500

1800 x 3200

2270 x 1600

2270 x 3200

2740 x 1600

2740 x 3200

3210 x 1600

3210 x 3200

Fig. 2-9 Basic device dimensions

Overall dimensions

(B x C) [mm]

2055 x 2512

2055 x 3412

2525 x 3412

2525 x 4112

2995 x 2512

2995 x 4112

3465 x 2512

3465 x 4112

3935 x 2512

3935 x 4112

Width B1

[mm]

300 624 830

Width B2

[mm]

Work surface

Height

(A) [mm]

2-16

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G3 series Product description

Technical information

Typ e Static material clea-

rance width

M-1600

M-2500

L-2500

L-3200

XL-1600

XL-3200

2XL-1600

2XL-3200

3XL-1600

3XL-3200

The work surface and material clearance width are dependent on the tool and the

1610

2080

2550

3020

3490

(D) [mm]

Material clearance

width with CV (D)

[mm]

1330

1800

2270

2740

3210

Material clea-

rance thickness

[mm]

61/31

module

Two versions are available

max.

Typ e Weight [kg]

floor load

[kg/m

]

M-1600

M-2500

L-2500

L-3200

XL-1600

XL-3200

2XL-1600

2XL-3200

3XL-1600

3XL-3200

670

840

970

1120

890

1290

980

1420

1120

1610

Typ e Max. weight proces-

sing material [kg]

M-1600

M-2500

L-2500

L-3200

XL-1600

XL-3200

2XL-1600

2XL-3200

3XL-1600

3XL-3200

340

450

580

370

740

440

880

520

1040

200

Max. weight processing material [kg/m

]

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2-17

Product description G3 series

Technical information

2.8.1.2 Cutter extension

Important!

Cutter extensions do not increase the work surface of the cutter. They serve as a transport belt extension for the feeding and removal of material

Fig. 2-10 Cutter extension dimensions

Cutter extension T1

Type

CE0800 745 

CE1250 1195 

CE1600 1545  

CE2500 2445 

CE3200 3145 

[mm]

M-1600

M-2500

L-2500

L-3200

XL-1600

XL-3200

2XL-1600

2XL-3200

3XL-1600

3XL-3200

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G3 series Product description

Technical information

2.8.2 Electrical connection, power consumption

Electrical connection 400 V, 50/60 Hz

Value Units

Voltage 3-phase, 400

L1, L2, L3, N, PE

Mains frequency 50/60 Hz

Power consumption - 3 phases(without

3.6 KW

vacuum generator)

Current consumption, 3 phases(without

max. 12 A

vacuum generator)

Mains fuse, min.

only applies for the basic device, the minimum requirement for the mains fuse

16 A

increases depending on the vacuum generator

Vacuum generator

For additional data see rating plate/original operating manual in chapter "Additional specifications"

The vacuum generator is selected according to the following criteria:

– Cutter model

– Desired application

– Local mains voltage and frequency

Vacuum generator 1 - 9 KW Value Units

Voltage 3-phase, 400 V

Mains frequency 50/60 Hz

Power consumption - 3 phases 1 - 9 KW

Mains fuse, min.

32 A

Vacuum generator 1 - 15 KW Value Units

Voltage 3-phase, 400 V

Mains frequency 50/60 Hz

Power consumption - 3 phases 1 - 15 KW

Mains fuse, min.

2.8.3 Environmental conditions

Operating temperature + 10 to + 35 °C

Storage temperature - 20 to + 55 °C

Relative humidity 10 - 80, non-

2.8.4 Basic device compressed air

Conveyor feeding clamps Value Units

Operating pressure 0.6 - 0.8 MPa

Min. air flow 20 l/min

32 A

Value Unit

condensing

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2-19

Product description G3 series

Technical information

Conveyor feeding clamps Value Units

Setting - pressure regulator maintenance unit (P3)

Control of vacuum zones, supply of various modules, tools

Operating pressure 0.6 - 0.8 MPa

Min. air flow 20 l/min

Setting - pressure regulator maintenance unit (P2)

Additional specifications and requirements can be found in the chapters "Modules, tools, options, material handling"

2.8.5 Control unit

Execution

4-axis control (X, Y, T, Z)

Variable, prognostic vector processing.

Software

Command set HP-GL, extended

Data format ASCII

0.6 MPa

Value Units

0.6 MPa

Interface

RS-232C / V24 600 - 38200 Baud

1 MB input buffer with replot function

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G3 series Product description

Technical information

2.8.6 Performance

Precision

Value Units

Resolution of measuring system 0.005 mm

Positioning accuracy at a constant temperature ± 0.1 mm

Repeat accuracy ± 0.03 mm

Evenness of the table ± 0.2 mm

Cutting performance

Value Units

Speed in the vector direction 1 - 1414 mm/s

Max acceleration in the vector direction

Max. permitted printing force of the printhead (creasing)

depending on the module equipment and cutter size

9.1 m/s

200 N

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Product description G3 series

Technical information

2.8.7 Emissions

Noise

Continuous sound pressure level of the cutter < 75 dB (A)

Depending on the tool system and materials to be processed:

– if the limit value of 85 dB (A) is exceeded,

– noise protection measures may be necessary

Important!

Protective measures against noise and emissions (dust, solvents, material residues etc.) for each tool system are specified in chapter 3.

Electromagnetic emissions

The G3 series meets requirements of the following technical standards:

• EN 61000-6-2 EMC, interference resistance in industrial environments

• EN 61000-6-4 EMC, emission standard in industrial environments

Please ask the manufacturer if you wish to refer to the test reports.

2.8.8 FCC approval

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.

NOTE:

Changes or modifications made by the user that are not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.

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G3 series Safety

General

3 Safety

3.1 General

Your safety – as the operator, service engineer or otherwise – is the primary concern. Certain situations, problems or faults that may occur on the equipment could put your safety at risk if you are not aware of the steps you should take to avoid the resulting dangers.

Contents

– Stipulation of the correct use of the machine

– Generally applicable safety instructions and safety regulations to be observed

– Explanation of the meaning of symbols and pictograms which are used in this

manual and in signs on the machine

– Location of safety and monitoring devices on the machine

– Information on protective equipment required and of requirements for operators

and maintenance personnel

Specific activity-related and situation-related safety instructions are given in the corresponding procedures in the following chapters of this manual and in other parts of the documentation.

Latest technology

The supplied machine meets the standards of the latest technology at the time of delivery.

However, the equipment may pose dangers unless the safety instructions in this guide are observed and implemented.

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3-1

Safety G3 series

Proper use

3.2 Proper use

The proper use of the machine is essential for its safe operation.

The equipment supplied:

• Is listed and labelled

• Determines the possible uses of the machine

The machine is intended for use as an output device for CAD/CAM data for the labelling and processing of materials arranged on the table.

The intended use and the limits of the application are dependent on:

• The module and tool system that is used

• The existing material transport system

Any other use or any use going beyond this scope constitutes improper use. The user bears sole liability for any damage arising as a result of improper use.

The operation of the machine is also seen as correct if:

• All nationally imposed safety regulations are complied with

• The safety instructions in this operating manual are observed

• The operating conditions are adhered to and the prescribed materials are used

3.3 Examples of improper use

Improper use of the machine can:

• Cause injury

• Result in serious damage to the machine

• Lead to loss of warranty

Improper use of the machine includes, among other things:

• Any structural modification to the machine carried out without written agreement from the manufacturer

• Use of unsuitable modules/tool inserts

• Servicing work performed by untrained or unauthorised personnel

• Installation of spare parts and use of accessories and resources not approved by the manufacturer

• Deliberate or careless interference with the machine during operation

• Commissioning of the machine – Without sufficient personal protection equipment – Without the designated protective and safety measures – If the operating manual is incomplete or not available in the local language

• Non-adherence to maintenance requirements

• Failure to react to signs of wear and damage

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G3 series Safety

Hazard warnings, important instructions

3.4 Hazard warnings, important instructions

3.4.1 Explanation of the hazard warning

Both in the operating manual and on the device itself, dangers, important instructions and user tips are designated by special symbols and signal words as follows.

Danger!

The safety instruction Danger

• Refers to an immediate threat

• Refers to operational and service risks

• Warns of serious effects on health and safety, including life-threatening injuries.

Warning!

The safety instruction Warning

• Refers to a dangerous situation

• Refers to operational and service risks

• Warns of serious effects on health and safety, including life-threatening injuries.

Attention!

The safety instruction Caution

• Refers to a dangerous situation

• Refers to operational and service risks

• Warns of minor injuries and other serious damage to the machine and secondary damage

Attention!

The safety instruction Caution without a hazard symbol

• Refers to a dangerous situation

• Refers to operational and service risks

• Warns of serious damage to the equipment, damage to other property and consequential damage

Important!

Refers to user tips and useful information which enhance the usability and prolong the service life of the machine and make the work significantly easier.

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3-3

Safety G3 series

Hazard warnings, important instructions

3.4.2 Structure of the hazard warnings

Example:

Warning!

Risk of poisoning from the emission of toxic dust

Processing certain materials can lead to the creation of toxic dust with significant risk to health.

• Obtain information about the toxicity of the material to be processed from the manufacturer

• Use a suitable extraction unit or take other appropriate action accordingly

Hazard warnings consist of the following units:

1 The hazard symbol of the appropriate signal colour

2 The signal word corresponding to the danger resulting from the situation

3 The description of the danger

4 The description of the consequences which could result from this hazardous si-

tuation

5 Possible actions and codes of conduct to prevent the hazard occu r r i n g o r t o av e r t

possible hazardous situations

3-4

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G3 series Safety

Areas of responsibility

3.5 Areas of responsibility

The manufacturer

• Is responsible for the safe condition of the machine on delivery, including instruction handbook and accessories, according to the sales documentation.

The owner or person authorised by him:

• Ensures that only adequately trained personnel, who have been properly instructed and have read and understood the content of the safety instructions in this chapter, will operate and maintain this machine

• Clearly determines the responsibility of the operators and service personnel as required in the instruction handbook

• Checks the personal protective equipment of operators and service personnel

• Is responsible for the safe condition of the machine

• Ensures that servicing and maintenance is carried out according to the maintenance schedule

• Notifies the manufacturer of any accident involving the machine that results in serious injury or substantial material damage

• Removes the machine from service immediately if defects arise that are detrimental to its operational safety

Operators and service personnel:

• Wear the necessary personal protective gear

• Halt operation immediately in the event of faults

• Report any changes which are detrimental to operational safety

• Keep the equipment clean

• Check the operation of the emergency stop switches before starting work

3.6 Personnel requirements

The operators and service personnel must meet the following requirements:

• Be physically and mentally suitable

• Be qualified by means of thorough training in the use of the machine

• Have read and understood the operating manual/service manual

• Be over the age of 16

• Have knowledge of first aid and the use of fire extinguishers

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3-5

Safety G3 series

Rules and safety at work

3.7 Rules and safety at work

• The operation of the machine is always subject to local regulations regarding safety at work and accident prevention.

• Before the machine is put into operation: Always check the safety equipment and protective covers.

• If a hazardous situation occurs, switch the machine from the ONLINE operating status to the STOPPED/OFFLINE operating status:

– Switching can be carried out by pressing the ONLINE button on the operating

unit

– By pressing one or more direction keys (emergency stop function).

• You are not permitted to make unauthorised modifications and changes to the machine which might affect the system's safety. Accessories or spare parts produced by other manufacturers may only be used with the machine with the written approval of the manufacturer.

• Only service personnel authorised by the manufacturer are permitted to install, commission, maintain and repair the machine.

• Before carrying out any maintenance, repair and modification work: – Switch the machine off using the on/off switch and secure with a lock – Prevent the machine being switched on inadvertently by removing the mains

supply cables to the distribution box (several mains connections).

3.8 Procedure in case of malfunctions

In principle, any troubleshooting work or inspection on the cutter is to be carried out only when it is switched off.

The following must never be by-passed or rendered ineffective:

• Light barriers and protective trip switches on the bar

• Monitoring sensors

• Safety and control switches in the machine

If malfunctions cannot be remedied by the operators using simple measures, then the responsible service station must be informed.

3-6

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G3 series Safety

Danger areas

3.9 Danger areas

3.9.1 General danger area

Fig. 3-1 General danger area

1 Danger area

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3-7

Safety G3 series

Danger areas

3.9.2 Danger area on the module carriage

Attention!

Risk of injury on the module carriage

The danger area on the module carriage is not secured using safety devices.

• Do not reach into the danger area during the manual initialisation

• Secure the danger area on the module carriage using the slot protective plates

Fig. 3-2 Danger area on the module carriage

1 Danger area

2 Slot protective plate

Place a slot protective plate on each module slot on which no module is installed.

3-8

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G3 series Safety

Danger areas

3.9.3 Danger area during the installation

Attention!

Risk of injury during the manual initialisation of the tool.

The safety devices are not active during the manual initialisation

• Do not reach into the danger area during the manual initialisation

• Use the automatic initialisation function for the initialisation

Fig. 3-3 Danger area during the installation

1 Danger area

2 Tool (e.g. EOT)

Safety distance during the manual initialisation

The safety distance (b) for operating personnel during manual initialisation is 25 cm. Do not reach into the danger area during the initialisation phase.

3 Example: Module 2

b Safety distance

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3-9

Safety G3 series

Working and traffic area

3.10 Working and traffic area

Warning!

There is a danger of injury to others through inappropriate behaviour or carelessness.

Please advise others to maintain an appropriate safety distance from the designated work and traffic zone.

Fig. 3-4 Working area around the cutter

A Working area - active area of the tool

B Working and traffic area of the operator

C Minimum safety distance for other personnel

Safety distance for other personnel

The safety distance for other personnel extends over the surface of the cutter plus a distance of at least one metre.

Working and traffic area

The working and traffic area extends over the surface of the cutter with fittings and options plus a distance of at least one metre.

Use with conveyor extension

When using a cutter extension, the loading and removal of material is permitted outside of the danger zone (working and active area).

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G3 series Safety

Safety signs

3.11 Safety signs

3.11.1 Responsibility of the operator

Warning!

Risk of injury due to a lack of safety signs

Risks and sources of danger cannot be localised due to the lack of safety signs.

• Replace missing or illegible safety signs as per Fig. 3-1

The operator is responsible for replacing missing/illegible safety signs on the machine. The appropriate safety signs can be requested from your service partner.

3.11.2 Position of the safety signs

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Fig. 3-5 Safety signs

1 Danger of hand injuries

2 Danger of electrical safety hazard

3 Laser beam warning

Important safety signs on the machine must be followed. Otherwise, this could result in serious injuries or death. Special module or tool specific signs can be found in the relevant operating manual.

4 Warning of the danger of cuts

5 Wear eye protection

6 Wear protective gloves

3-11

Safety G3 series

Safety signs

Warning!

Safety risks due to missing or illegible safety signs.

Check all safety signs on a regular basis for legibility and completeness.

Replace missing or illegible safety signs promptly with new original signs.

Meaning of safety signs

The symbols on the safety signs

– have specific meanings

– are located wherever certain behaviour is prohibited due to it being potentially

dangerous

Prohibition signs

– are round and red-coloured

– are located wherever certain behaviour is prohibited due to it being potentially

dangerous

Order signs

– are blue and circular

– Stipulate the wearing of personal protective equipment to protect against ha-

zards

Wear eye protection

Wear protective gloves

Fire protection signs

– are rectangular and red-coloured

– Are intended to draw attention to equipment and information for use in the event

of a fire

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G3 series Safety

Safety signs

Warning signs

– are triangular and yellow-coloured

– Are intended to draw attention to objects and circumstances which represent a

potential danger to life and limb.

Danger of hand injuries (crushing)

Danger of hand injuries (severing)

Danger of electrical safety hazard

Laser beam warning

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3-13

Safety G3 series

Safety and monitoring devices

3.12 Safety and monitoring devices

Fig. 3-6 Safety and monitoring devices

1 Emergency stop switch

2 Protective system

3 Operating unit

3-14

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G3 series Safety

Safety and monitoring devices

3.12.1 Protective system

Attention!

If there is a collision, the bar may cause serious injuries.

The high level of kinetic energy of the drive results in a braking distance which cannot be ignored.

Light barriers and safety cut-offs are no guarantee against injuries.

The protective system is made up of protective trip switches and light barriers on the ends of the bar.

Protective trip switches and light barriers are part of a self-monitoring safety shutdown system.

If protective trip switches or light barriers cause an obstruction then the following protective measures are introduced:

– An emergency stop halts all movements

– The operating status STOPPED is activated

– An error message is displayed

Protective trip switches

Protective trip switches trigger the safety shut-down if they are touched by an obstruction. They are used as hand protection.

Light barriers

The working area is monitored by light barriers on the front and rear side of the beam.

Important!

The light barriers are active in all operating states.

3.12.2 Operating unit

Malfunctions are indicated on the LCD display.

An acoustic signal is emitted in the case of emergency stop and to acknowledge keypad entries.

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3-15

Safety G3 series

Safety and monitoring devices

3.12.3 Emergency stop switch

– Emergency stop switches are part of a protective circuit

– They allow the machine to be turned off quickly in hazardous situations

Two emergency stop switches can optionally be fitted on the edges of the machine.

The mains power supply to the whole machine is switched off as soon as the emergency stop switch is pressed. The operating unit remains switched on.

Attention!

Pressing the emergency stop switch can damage the cutter.

Do not press the emergency stop switch to switch off the machine in routine operation.

Important!

To unlock an activated emergency stop switch after regaining operational safety, turn the switch anticlockwise (see chapter "Controls and operation").

3.12.4 Safety cut-off feature

The following safety measures are introduced when an overload occurs or an axle drive (T, X, Y, Z) is blocked:

– An emergency stop is carried out

– The cutter switches to the operating status STOPPED

– An error message and an alert buzzer indicate the safety cut-off

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G3 series Safety

Personal protective equipment, clothing

3.13 Personal protective equipment, clothing

The safety equipment required for operating the machine is dependent on the following factors:

– The module and tool system

– The material to be processed

When operating the machine or carrying out maintenance or servicing work, wear close-fitting clothing and the appropriate personal protective equipment.

Warning!

Risk of injury from being caught or trapped in moving machine parts.

• Do not wear loose clothing, scarves, open jackets or open shirt sleeves.

• Remove all jewellery before starting maintenance and servicing work.

Personal protective equipment comprises:

• Work clothes (service personnel),

• Protective goggles (operators, service personnel): – To provide protection from particles during cutting operations – To protect the eyes from dangerous radiation – To protect the eyes from chemicals

• Protective gloves where injury is possible due to: – Burns – Sharp or pointed objects

• Chemical-resistant protective gloves where injury is possible due to: – Chemicals (cleaning agents)

• Breathing protection when working with poisonous substances

• Ear protection if the continuous sound pressure level is over 80 dB.

Important!

You are personally responsible for:

• Using the required personal protective equipment

• Cleaning and maintaining the equipment on a regular basis

• Replacing damaged and unusable elements of protective equipment in a timely fashion

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3-17

Safety G3 series

Mechanical hazards

3.14 Mechanical hazards

3.14.1 Gathering, retraction

Hazards caused by the bar, modules or the tool system during gathering and retraction

Possible consequences:

• Cuts, bruising and crushing of fingers and hands

• Bruising of head and arms

• Tearing out of hair

• Damage to clothing

• Damage to the machine

Precautions during the initialisation and the operation in the ONLINE operating status:

• Do not touch tool head and bar

• Do not enter the working/active area

• Do not touch table surface and material to be processed

• Do not lay your hands on side covers

• Do not lean over the working surface

• Avoid leaving long hair loose and wearing loose clothes and ties

These precautions specifically apply if the cutter can be switched into ONLINE operating status by the CAD/CAM system.

3.14.2 Gathering, impacts of foreign objects

Foreign objects on the table are grasped and pushed away by the bar and the tool head.

Possible consequences:

• Facial injuries and other injuries due to objects being pushed away

• Damage to the machine

Precautions during the initialisation and the operation in the ONLINE/OFFLINE operating status:

• Do not place materials, tools or other objects on the table or side covers

• Before operation, check whether there are any objects on the table or the side covers

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G3 series Safety

Risk of burns

3.14.3 Cuts and stab wounds

Knives, routers and punching inserts have very sharp edges which are sometimes hidden by moving equipment (slipper spring).

Possible consequences:

• Cuts and stab wounds to the hands and arms

Precautions during the knife change, initialisation and the operation in the ONLINE operating status of the machine:

• Be extremely careful when changing the tool inserts

• Do not enter the working area during the initialisation and during operation in the ONLINE operating status

3.15 Risk of burns

Certain materials (metals) and tools (router) reach very high temperatures during processing.

Possible consequences:

• Burns on the limbs

Precautions:

• Allow workpieces to cool before removing them

• Wear suitable protective gloves when removing workpieces that have just been processed

• Allow tools (router, knife) to cool before removing them

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3-19

Safety G3 series

Electrical hazard

3.16 Electrical hazard

Warning!

Risk of death or injury from electric shock.

The machine is operated with a mains voltage of 380 V, system frequency of 50/60 Hz.

Safety instructions

• Only trained service personnel are authorised to open switch boxes and electronics units.

• Ensure that mains cables are protected against mechanical loading and are laid so that they are free from strain.

• Replace damaged cables immediately.

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G3 series Safety

Risks arising from the emission of toxic dust

3.17 Risks arising from the emission of toxic dust

Warning!

Risk of poisoning from the emission of toxic dust

Processing the most wide-ranging materials can lead to the creation of toxic dust with significant risk to health.

• Obtain information about the toxicity of the material to be processed from the manufacturer.

• Use a suitable extraction unit or take other appropriate action accordingly.

The company operating the system is responsible for making sure that all national regulations concerning the maximum permissible dust concentration at work are adhered to. When handling hazardous types of dust, all local safety regulations as well as the manufacturer's instructions must be observed. Use special vacuum cleaners with specially adjusted dust filters if you are routing/processing hazardous materials. Zünd offers suction systems which meet the following regulations as accessories:

– The extraction of hazardous dusts with a maximum concentration at work of up

to 0.1 mg/m

– The extraction of dusts conforming to dust class H

and the extraction of wood dusts of dust class M

3.18 Risks arising from the processing of toxic/hazardous materials

Warning!

Risk of poisoning from emissions when processing toxic materials

Processing the most wide-ranging materials can lead to toxic emissions (gases, dust etc.) with significant risk to health.

• Never process toxic/hazardous materials!

• Obtain information from the manufacturer of the material to be processed about its toxicity.

Guidelines

• The company operating the system is responsible for establishing which processing materials are toxic/hazardous.

• It is prohibited to process toxic materials on Zünd cutters without appropriate additional safety measures!

• The company operating the system is responsible for installing appropriate additional safety measures!

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3-21

Safety G3 series

Environmental hazard

3.19 Environmental hazard

Warning!

Processing residues, operating fluids etc. can cause damage and pollute the environment if they enter the soil, watercourses or the sewage system.

Explanation of the hazard label

Hazard label for substances that are harmful to the environment

Safety regulations and protective measures

• Dispose of waste materials in accordance with current national environmental protection regulations. In case of doubt, check the appropriate disposal methods with your local collection point or recycling centre.

• Collect different chemicals in separate containers.

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G3 series Safety

Handling and storage of chemicals

3.20 Handling and storage of chemicals

Warning!

Cleaning agents, operating fluids etc., can cause skin irritation and can therefore be hazardous to health if handled carelessly.

Always wear personal protective equipment when working with chemicals.

Explanation of the hazard label

Hazard label for toxic substances

Hazard label for harmful substances

Hazard label for irritating substances

Important!

Chemicals classed as irritants are used to operate and clean this machine (cleaning agents, operating fluids). Safety datasheets of the substances in question can be downloaded from the Zünd homepage (www.Zund.com).

Safe handling of chemicals

Disposal!

Dispose of chemicals in accordance with national regulations.

• Store chemicals in tightly closed containers in a cool dry place (between 5 °C and 30 °C).

• Protect the containers from heat and direct sunlight.

• Provide good ventilation, including at floor level.

• Store chemicals in accordance with local regulations.

• Keep containers tightly closed.

• Use chemicals only for the intended purpose.

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3-23

Safety G3 series

Risk of fire and explosion

3.21 Risk of fire and explosion

Warning!

There is a risk of fire when routing and cutting inflammable materials

Terminate the routing/cutting and leave the tool to cool in the case of

• Formation of smoke

• Discolourations on the router/knife which point to increased heat development

Warning!

Risk of dust explosions

Flying sparks or electrostatic charges result in the risk that there will be dust explosions during the extraction of different materials.

• Obtain information about the risk of explosion when processing the type of material that you are using.

• If necessary, adjust the extraction to the required regulations.

Fire classes

Refer to the following table to find out which type of fire extinguisher is used for each fire class:

A Solid materials, mainly organic in nature; e.g. wood, paper, textiles, etc.

B Liquid and liquefiable substances; e.g. petrol, oils, greases, paints, etc.

C Combustible gases: methane, propane, etc.

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G3 series Safety

Danger caused by laser beam (laser pointer)

In the event of a fire:

• Switch off the machine (emergency stop switch)

• Assess the situation: If the situation is dangerous, leave the area immediately and call the fire brigade. Only try to extinguish the fire if your personal safety is not at risk.

• Remove a suitable fire extinguisher (A, B, C) from its bracket and prepare it for use.

• Locate the source of the fire. Attack the fire with repeated short bursts from the extinguisher. Always spray the extinguishing agent into the source of the fire. In other words, always aim at the burning material and not at the flames.

• After using the fire extinguisher, do not return it to its usual place but have it refilled immediately.

Observe the following safety rules and countermeasures

• Find out the number of locations where fire extinguishers are kept and familiarise yourself with their use. The adjacent sign indicates the location of a fire extinguisher.

• Do not use inflammable cleaning agents to clean the machine.

• Store all processing materials in the proper manner in accordance with local guidelines.

3.22 Danger caused by laser beam (laser pointer)

Class 2 lasers are used as laser pointers. Momentary irradiation of the eyes, as can occur if you accidentally look directly at the laser, is not dangerous. In addition, depending on the construction, the laser beam is targeted directly at the material to be processed.

Safety instructions

• Avoid direct, prolonged eye contact

3.23 Safety instructions for operators

This instruction manual cannot cover all possible situations and potential hazards.

It is therefore particularly important that operators

• have been thoroughly trained and are aware of and able to correctly assess the hazards that can arise from the machine

• are familiar with all safety devices on the machine

• request information from the manufacturer without delay if an undocumented, hazardous situation arises in connection with the machine

In addition to these safety instructions, you must also observe the situation-related safety notes in the chapters "Controls and operation" and "Maintenance and cleaning".

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3-25

Safety G3 series

Safety precautions for service personnel

3.24 Safety precautions for service personnel

The reliability, readiness and service life of the machine greatly depend on you carrying out your work in a conscientious manner.

Important!

Specialist knowledge and expertise are required to service and maintain the machine. The manufacturer provides this knowledge through training courses which are specially tailored for service personnel. Only personnel with Zünd certification are permitted to carry out service work on Zünd cutters.

3.25 Disposal

Disposal!

Information about proper disposal

• Identifies toxic substances that are harmful to the environment

• Relates to the disposal of harmful substances

• Warns against disposal with domestic waste or environmental pollution caused by hazardous substances and objects contaminated with such substances

Measures for disposal

Zünd cutters correspond with the requirements of the German Electrical and Electronic Device Act and generally do not contain any poisonous substances or consumables.

Contact Zünd customer services or your service partner before you dispose of your cutter.

Dispose of cutting waste in accordance with current national environmental protection regulations. In case of doubt, check the appropriate disposal methods with your local collection point or recycling centre.

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G3 series Controls and operation

General

4 Controls and operation

4.1 General

This chapter familiarises you with the controls, guides you through the operational procedures and describes the following operating steps:

– Daily commissioning

– Operation of the main components

– Detailed information on the operation of the machine

– Safe switching off of the machine

4.2 Safe working practices

Danger!

Operating errors or negligence can put human lives at risk as well as causing serious damage to the machine.

The machine is fitted with safety devices to minimise risk. However, these safety devices cannot guard against damage as a result of operating errors or negligent working practices.

• Observe the safety requirements from the chapter "Safety" and the situational safety requirements of the appropriate working step.

As the operator, you are responsible for the safe use of the machine.

You must observe the following:

– The safety instructions given in "Safety"

– The information contained in this chapter, bearing in mind the training provided

by the manufacturer or retailer

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4-1

Controls and operation G3 series

Controls

4.3 Controls

4.3.1 Control panel

Fig. 4-1 Control panel

1 Switch unit

2 Emergency stop switches

3 Operating unit

4-2

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G3 series Controls and operation

Controls

4.3.1.1 Operating unit

Fig. 4-2 Operating unit

1 Display

2 Soft keys

3 Navigation keys

4 Numerical keys

VAC

key (vacuum)

6 Coordinate system (axes)

STOP

key

ONLINE

SHIFT

10 Travel keys

Tool up/down

12 Function keys

key

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4-3

Controls and operation G3 series

Controls

4.3.1.2 Navigation keys

Fig. 4-3 Navigation keys

Key Function in the cutter menu

Use these keys to navigate through the menu

• If submenus are available, use this key to change to the next menu level

• Select setting/function

Change from a submenu or a setting to the previous menu level

Key Function in the editor

Use these keys to move the cursor to the right or left

4.3.1.3 Numerical keys

Fig. 4-4 Numerical keys

Functions of the numerical keys

• Direct entry of the menu number

• Entry of values when there is a prompt

4.3.1.4 Function keys

4-4

Fig. 4-5 Function keys

Important functions are distributed to the function keys and therefore can be selected directly. It is possible to programme the respective function of the function keys.

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G3 series Controls and operation

Controls

4.3.1.5 Travel keys

Fig. 4-6 Travel keys, shift key

1 Move module forwards

2 Move module to the left

3 Move module backwards

These keys are used to move the module unit in the operating statuses STOPPED and OFFLINE.

If work is being carried out in the ONLINE operating status and a travel key is pressed then the operating status changes to OFFLINE.

4.3.1.6 Soft keys

Fig. 4-7 Soft keys

These keys change their function depending on the situation. The currently valid function is shown in the display.

4 Move module to the right

5 SHIFT key

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4-5

Controls and operation G3 series

Controls

4.3.1.7 Special keys, shortcuts

Important functions are defined with separate keys on the operating unit:

Current

operating status

STOPPED Switch off the machine Change to OFFLINE

ONLINE Switch off the machine

OFFLINE Switch off the machine

Current

operating status

Vacuum off Switch vacuum on

Vacuum on, suction

Vacuum on, blowing

Current

position

Up Z pos

Down Z pos Raise tool into upper position

Park position - Lower tool into upper position

With SHIFT key Without SHIFT key

Switch vacuum off

With SHIFT key Without SHIFT key

Lift tool into park position

Function

Change to STOPPED

Function

Vacuum menu

Function

Lower tool into lower position

Current

operating status

ONLINE

OFFLINE

STOPPED

Function

See section 4.6.3

4-6

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G3 series Controls and operation

Controls

4.3.2 Emergency stop switches

Attention!

Risk of damage to the machine.

Only use the emergency stop switches to switch off the machine in an emergency not for standard shutdown.

• Emergency stop switches are part of a protective circuit

• They allow the machine to be switched off quickly in a dangerous situation

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Fig. 4-8 Emergency stop switches

The machine is fitted with four emergency stop switches as standard. They are located as follows:

• 1 x on the operating console

• 3 x on the side support covers

Consequences of pressing an emergency stop switch:

• The drive motors are brought to a standstill and then are isolated from the energy supply

• Safety-related units (modules, tools, auxiliary drive, sheet feeder, etc.) are isolated from the energy supply

• Units that are not safety-relevant or that are important for the operation of the device (vacuum, operating unit, dust extractor, compressor, etc.) remain switched on

4-7

Controls and operation G3 series

Controls

Important!

An emergency stop switch that has been pressed remains locked in the off position.

To unlock an activated emergency stop switch after regaining operational safety, turn the switch anti-clockwise.

Procedure

⇨ When a hazard or a possibly hazardous situation occurs,

press an emergency stop switch without delay

✓ All machine movements are stopped. The emergency stop

switch that has been pressed remains locked in the off position

⇨ Regain operational safety.

⇨ Turn the emergency stop switch clockwise until it is

unlocked

⇨ Use

Function test

to reinitialise the machine

Danger!

Risk of injury due to defective emergency stop switches

Machines with defective emergency stop switches are not safe for operation. In hazardous situations the machines cannot be stopped promptly.

• Check that the emergency stop switches are working on a daily basis.

• Do not start up a machine with defective emergency stop switches until the problem has been remedied by authorised personnel.

4-8

⇨ Press all emergency stop switches before the start of work/after the initialisation

of the device

✓ If the machine stops correctly then it is safe for operation

Problem solution

The machine does not stop correctly following the activation of an emergency stop switch.

⇨ Do not start up the machine. Let authorised personnel remedy the problem.

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G3 series Controls and operation

Controls

4.3.3 Maintenance unit

The maintenance unit adjusts the air pressure to the switching of the vacuum elements/various modules and options.

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Fig. 4-9 Maintenance unit

1 Stopcock

2 Water separator

3 Air pressure setting for various

modules, vacuum elements (P2)

The maintenance unit is preset and adjusted.

Check the air pressure setting at regular intervals. The settings can be found in the chapter "Product description", "Specifications".

4 Air pressure setting for conveyor clamp

elements and feed elements (P3)

5 Fixing bracket for an additional, optional

maintenance unit for various modules, tool inserts and options

4-9

Controls and operation G3 series

Controls

4.3.4 Interfaces

The machine has interfaces for data exchange. These are attached to the electronics unit.

Fig. 4-10 Interfaces

1 LAN

2 Not used

3 USB (Host)

4 Status and error display

5 COM 1

6 COM 2

4-10

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G3 series Controls and operation

Menu navigation

4.4 Menu navigation

4.4.1 Menus and functions

Navigation

The cutter has a large number of functions. The current menu number and the current menu are displayed in the header.

Fig. 4-11 Current menu number, menu

Graphic layout

Symbol Description

Blocked menu (user level)

Value/entry/command

Display of a value

Navigation in the menu

⇨ Use the navigation keys to scroll through the menu and use to

select a submenu/a function (e.g. Tools).

⇨ To return to the previous menu level press the navigation key . Press

to return back to the main menu.

Direct selection of menus

Each menu and each function is allocated a unique menu number. It is possible to change between menus by entering the menu number. Two-figure menu numbers (10, 11 etc.) are displayed in lower positions.

ESC

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Commands/functions

Commands are carried out immediately after the entry.

⇨ Use the navigation keys to mark the required command and select

using .

⇨ The command can be triggered directly via the menu number. In order to do this,

enter the menu number on the control panel

An exception to this rule is made for safety-relevant commands (e.g. automatic moving). These can be confirmed using OK or cancelled using ESC.

4-11

Controls and operation G3 series

Menu navigation

Value/entry

⇨ If a flashing cursor appears on the display below a number, then a number input

is required

⇨ Enter the required value using the numerical keys

⇨ Check the value and confirm using OK or cancel the entry using ESC

Select

⇨ Use the navigation keys to select an entry from the list

⇨ Confirm using OK or cancel using ESC

Default settings (factory setting)

Default settings are available for many functions/values.

⇨ Select function

⇨Use Def to reset the value to the factory setting

Min/max settings (factory setting)

Limit values are available for many functions/values.

⇨ Select function

⇨Use Min/Max to set the value to the upper/lower limit value

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G3 series Controls and operation

Menu navigation

4.4.2 Help

Help texts are available for important menu entries. In order to display a help text,

mark the required menu and press the key.

4.4.3 Info menu

Within the menu the Info menu can be activated with the key.

Use the keys to switch between tabs. Use the keys to scroll up/

down within the tab.

Tabs

Tab Information

Head Information on the module carriage

Module Information on the module

Position Specification of the current position of the current tool

Buffer Information on the memory system

Job Information on the print job

Status Display of the user level, the operating status, etc.

Function keys Allocation of the function keys

Communication Communication settings such as: interface, port, IP

address, mask, MAC address, etc.

4.4.4 Popups/dialogues

Popup menus/dialogues are displayed for the following actions:

• Error messages (dialogue)

• Cutter status display (dialogue)

• Menus that are called up using function keys (popup)

The system changes back to the previously active menu when a popup or a dialogue is closed.

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4-13

Controls and operation G3 series

Menu navigation

4.4.5 User level

Access to menus and functions is blocked according to the user level. The user levels have a hierarchical structure. This means that the next highest user also has the access rights to the menu functions that the subordinate user has.

User level Description

Users 1 - 3 All menus and functions that are needed for the operation

of the machine are accessible

Operator Simple, uncomplicated settings work is permitted

Service Cutter settings that can only be carried out by authorised

service personnel

Factory setup -

Change user levels

⇨ Change to the menu

⇨ Enter your user code.

✓ The user level is approved and is displayed under

Password

4-2.

User

4-1.

Problem solution

The system does not change to the required user level.

⇨ Check the user code for your user level and repeat the entry.

Defining active user level after start-up

Important!

After start-up it is not possible to define a user level that is higher than your own as an active user level.

⇨ Change to the menu

⇨ Select the desired user.

✓ The selected user level will be active the next time the cutter is started.

Changing the passwords for user levels 2 and 3

Start user

4-3.

Important!

The passwords for user levels 2 and 3 can be changed in the Operator user level or higher.

4-14

⇨ Change to the menu

⇨ Select user.

⇨ Enter the new password for that user.

Change password

4-4.

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G3 series Controls and operation

Menu navigation

4.4.6 Function keys

The cutter has function keys (F1 - F8) which can be allocated menu functions. These keys can be selected via the menu or directly.

Allocate function keys directly

⇨ Press the SHIFT key and the function key (F1 - F8) which you wish to change at

the same time

⇨ The window for function key selection opens

⇨ Use the number field to enter the menu number of the required menu entry

⇨ Confirm using OK or cancel using ESC

Allocating the function key via the menu

⇨ Select the menu

⇨ Enter the numbers 1 - 8 for the respective function key F1 - F8

⇨ The window for function key selection opens

⇨ Use the number field to enter the menu number of the required menu entry

⇨ Confirm using OK or cancel using ESC

Resetting a function key to the factory setting

⇨ Change to the menu

⇨ The window for function key selection opens

⇨ Press the

⇨ Confirm using OK or cancel using ESC

DEF

Function keys

key in order to activate factory settings

6-5

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4-15

Controls and operation G3 series

Functions

4.5 Functions

4.5.1 Set language

It is possible to select the display language of the cutter.

⇨ Select the

⇨ Select the required language from the list and confirm

4.5.2 Set display

Setting the contrast

Key Description

Shift + Increase contrast

Shift + Reduce contrast

Switch lighting on/off

⇨ Shift + must be pressed to switch the display lighting on/off

Language

6-1 function from the menu

4.5.3 Setting the volume of the signal

Key Description

Shift + Increase/decrease the volume

4.5.4 Delete data buffer

Delete the data buffer following the termination/processing of a job.

Menu Description

2-5-1 Delete data buffer

4-16

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G3 series Controls and operation

Operation

4.6 Operation

4.6.1 Daily checks prior to start-up

Attention!

There is a risk of injury if the machine is defective.

Faults on the machine may be the cause of malfunctions and accidents - never start up a defective machine.

• Report all defects and faults to your supervisor and arrange for them to be rectified immediately by qualified personnel.

Inspection

Ensure that all maintenance and service tasks are performed in accordance with the maintenance schedule.

Before starting up the machine each day, perform a walk-round of the machine and check the following:

• Check the machine for visible damage

• Remove local dirt caused by processing materials and dust

• Remove objects from the processing table/the side supports

• Check whether all maintenance and service covers are installed correctly

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4-17

Controls and operation G3 series

Operation

4.6.2 Start-up

Switching on the machine

4-18

Fig. 4-12 Switching on the machine

⇨ Switch the main switch to position ON (1)

✓ The cutter switches on. The start page appears on the display

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G3 series Controls and operation

Operation

Initialising the machine

Attention!

⇨ Risk of injury due to automatic starting of the machine

⇨ Following initialisation, the operating status OFFLINE is active. The cutter can

receive commands from the operation software which activate the operating status ONLINE.

⇨ Only switch on the operation software following the initialisation of the machine.

⇨ Press the function key .

✓ The machine is initialised

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4-19

Controls and operation G3 series

Operation

4.6.3 Operating status

The cutter can be switched into three operating statuses depending on the purpose:

–OFFLINE

–ONLINE

– STOPPED

A combination of keys can optionally be used to switch from any operating status to either of the other two operating statuses.

The current operating status is displayed in the header of the main menu and with the LED of the ONLINE key.

The following graphic illustrates how the desired operating status is activated.

Fig. 4-13 activate operating status

4-20

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G3 series Controls and operation

Operation

4.6.3.1 OFFLINE

Attention!

Risk of injury due to automatic starting of the machine

In the OFFLINE operating status, the cutter receives commands from the operating software. These commands can be used to switch to the operating status ONLINE.

• Activate the operating status STOPPED during breaks.

• Always carry out set-up work in the operating status STOPPED.

A red flashing LED on the ONLINE key indicates that the operating status OFFLINE is active.

When the machine is switched on, the operating status OFFLINE is active.

In this status, commands are received from outside but they are not processed.

Operating software commands can be used to switch to the operating status ONLINE.

4.6.3.2 STOPPED

Important!

The operating status STOPPED protects the operator from the machine being set into motion using remote controls.

A red illuminated LED on the ONLINE key indicates that the operating status STOPPED is active.

In this operating status, commands (e.g. HPGL) are received but they are not processed. Even commands from the operating software (e.g. to change to the ONLINE operating mode) are ignored.

⇨ must be pressed in order to activate the operating status STOPPED. The

displays shows the following message:

⇨ Use to switch from the operating status STOPPED to ONLINE or us e S H I F T

to switch to the operating status OFFLINE in order to reactivate the remote

control.

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4-21

Controls and operation G3 series

Operation

4.6.3.3 ONLINE

A green illuminated LED on the ONLINE key indicates that the operating status ONLINE is active.

Commands are received and processed in this operating status.

⇨ must be pressed in order to activate the operating status ONLINE. The

displays shows the following message:

⇨ Use to switch from the operating status ONLINE to the operating status

STOPPED or use to change to the operating status OFFLINE.

4-22

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G3 series Controls and operation

Operation

4.6.4 Moving the bar/module manually

Fig. 4-14 Moving the bar/module

The module carriage can be moved using the travel keys in the operating status OFFLINE. The assignment of keys corresponds to the direction of travel.

Pressing the SHIFT key at the same time will make the module carriage move faster.

Pressing travel keys in the X and Y direction at the same time will make the module carriage move diagonally.

If one or more travel keys are pressed in the operating status ONLINE then an emergency stop is triggered.

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4-23

Controls and operation G3 series

Handling modules/tools

4.7 Handling modules/tools

Modules are independently recognised by the cutter control unit. Tools, on the other hand, do not have automatic recognition and must be manually allocated to a module.

Tool-specific parameters (initialisation, moving speeds, acceleration) are saved to the corresponding tool and can be called up again at any time.

4-24

Fig. 4-15 Tool handling

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G3 series Controls and operation

Handling modules/tools

4.7.1 Module/tool/tool insert

Fig. 4-16 Module carriage/module/tool/blade, router, etc.

1 Module (e.g. RM, UM)

2 Tool (e.g. 1000 W motor spindle, oscillating tool)

3 Module carriage (e.g. 3-way)

4 Router, blade, etc.

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4-25

Controls and operation G3 series

Handling modules/tools

4.7.2 Set module/tool change position

(can be set at operator user level or higher)

Fig. 4-17 Example: module carriage position for changing the module

1 Example: module carriage position 1 for changing standard modules

2 Example: module carriage position 2 for changing RM-A

Any two positions can be selected for module changes.

⇨Select 1-5-7

⇨Select 1-5-7-2

⇨ Use the module carriage to move to the required position and confirm using OK.

⇨ In menu 1-5-7-1

be carried out: Position 1: Module change in position 1 Position 2: Module change in position 2 Position 1 and position 2: After selecting choose between position 1 and position 2.

Module/tool change pos

Position 1

Position

to set position 1 and 1-5-7-5

, select the position in which the module change should

Change module/tool

Position 2

1-5-1, the user can

to set position 2.

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G3 series Controls and operation

Handling modules/tools

4.7.3 Inserting/replacing the module

4.7.3.1 Module mount

Fig. 4-18 Module mount

1 Locking mechanism

2 Mounting ledge

3 Electrical connection

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4-27

Controls and operation G3 series

Handling modules/tools

4.7.3.2 Inserting/replacing the module (e.g. UM)

Fig. 4-19 Inserting a module

⇨Select

change position.

⇨ Place the module on the mounting ledge as in Fig. 4-19, step A.

⇨ Tilt the module backwards onto the module carriage

⇨ Lower the module until it stops

⇨ Use the 4 mm Allen key to fix the module in place

✓ The module is now mounted and is located by the software

Change module/tool

1-5-1. The module carriage moves to the module

Problem solution

The module cannot be lowered.

⇨ Loosen the module locking mechanism before insertion

4-28

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G3 series Controls and operation

Handling modules/tools

4.7.4 Activating a module

It is often useful to activate a module/tool in order to check settings. This function can only be carried out in the main menu.

⇨ Activate the required module.

Module Key combination

Module 1 Shift + 1

Module 2 Shift + 2

Module 3 Shift + 3

ICC camera Shift + 8

Laser pointer Shift + 9

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4-29

Controls and operation G3 series

Handling modules/tools

4.7.5 Tool handling

4.7.5.1 Marking the tool (e.g.)

4-30

Fig. 4-20 Marking the tool (e.g.)

⇨ Label all tools of the same type with a consecutive number. Appropriate adhesive

labels are supplied with the equipment.

4.7.5.2 Switching the tool manager on/off

The tool manager is a user interface for handling tools in combination with a universal module (UM). A sensor detected the presence of the tool in use!

The tool manager helps to carry out the following:

• Insert tool

• Attach/select a tool

• Initialise a tool

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G3 series Controls and operation

Handling modules/tools

4.7.5.3 Tool manager — change tool (UM module)

⇨Select

⇨ If necessary, select the module/tool change position.

⇨ Insert the tool and connect the power supply if it is driven electrically or

pneumatically.

⇨ Press OK to confirm.

✓ The tool manager opens.

Tool manager — functions

1 Use to switch to menu

(see section 4.7.6)

2 Use Init to switch to the menu for manual or automatic initialisation. After

initialisation the parameters are saved. The tool manager closes and the main menu appears.

3 Confirm the tool selection with OK. The parameters previously used for this tool

remain in place.

Change module/tool

1-5-1.

Tool type

1-1-1-1 in order to select the inserted tool.

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4-31

Controls and operation G3 series

Handling modules/tools

4.7.6 Attaching/selecting a tool

4.7.6.1 Creating a new tool

⇨ Insert the marked tool into the module.

⇨Select

⇨ Select NEW

Tool type

1-1-1-1 in the menu.

⇨ The popup menu

⇨Select

⇨ All tool types that can be used in the current module are displayed in the popup

⇨ Enter the appropriate number of the tool in the popup menu

confirm using OK

Tool type

4.7.6.2 Selecting a tool

⇨ Insert tool.

⇨Select

⇨ In the

⇨ Select the inserted tool.

Tool type

Create new entry

. Select the tool from this list and confirm using OK

opens

Tool number

1-1-1-1 in the menu.

dialogue all tools assigned to this module are listed.

and

4-32

4.7.6.3 Deleting a tool

⇨Select

⇨ In the

⇨ Select a tool.

⇨ Delete the selected tool with Delete.

Tool type

1-1-1-1.

dialogue all tools assigned to this module are listed.

4.7.6.4 Saving tool-specific cutter settings

⇨ Use ESC to change to the main menu.

✓ The tool-specific settings that have been made are automatically saved.

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G3 series Controls and operation

Handling modules/tools

4.7.7 Inserting and connecting a tool (e.g. oscillating tool)

Ensure, that following preconditions are fulfilled:

❏ The machine is switched off and is in the operating status STOPPED

❏ The module is now mounted and has been located by the control unit

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Fig. 4-21 Insert tool

1 Bayonet catch 4 Positioning spindle

4-33

Controls and operation G3 series

Handling modules/tools

2 Module lock 5 Positioning bracket

3 Connector socket

Important!

The tool holder and a holding fixture are each marked with a red dot. The tool is in the correct position when the dots are aligned.

⇨ Move the module to the lower right-hand corner

⇨ with to switch to the STOPPED operating status

⇨ Insert the selected tool into the module holder. Ensure that the red point on the

module is located above the module lock

⇨ Lower the shaft of the tool into the module opening until it stops

⇨ Press the module lock and latch the bayonet catch

⇨ Turn the tool in a clockwise direction until the first notch on the positioning

bracket engages with the positioning spindle

⇨ Connect the tool to the connector socket

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000010,10,05-2010, jmu

G3 series Controls and operation

Handling modules/tools

4.7.8 Connecting driven tools - allocating port

Driven tools (e.g.: EOT, DRT, POT) require an energy supply (electrical, pneumatic). This energy supply is controlled by the cutter control unit. Electrically driven tools are inserted into the intended port on the connector control of the laser pointer/ICC camera. Pneumatically driven tools are already internally connected to the compressed air supply. A port is allocated to each individual connection which must be assigned via the cutter control unit before the initial commissioning of the respective tool. There are 3 electrical connections (ports) available on the distributor of the laser pointer/ICC camera. Pneumatic tools can be assigned to other ports.

4.7.8.1 Connection - electrical tools (EOT, DRT, etc.)

Fig. 4-22 Connection - electrical tools

1 Connection 1 = port 1

2 Connection 2 = port 2

3 Connection 3 = port 3

Procedure

⇨ The tool is attached and allocated to the module

⇨ Insert the tool into the connection provided

⇨ Use

✓ The tool is ready for use

Tool connector

corresponding port

1-1-1-3-1-1 to allocate the tool connection to the

000010,10,05-2010, jmu

4-35

Controls and operation G3 series

Handling modules/tools

4.7.8.2 Connection - pneumatic tools

Pneumatically driven tools and modules are connected to the interface unit on the module carriage. The pressure is set using a maintenance unit. The air supply is connected to the local installation or supplied via a compressor. The connection data and connection procedure may be found in the operating instructions for the appropriate tool/module.

Important!

Always use a stopper to protect connection P4 from dirt in the air supply. If particles of dirt reach the tool, it will be damaged.

Interface unit - connections

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Fig. 4-23 Interface unit - connections

P1 PUM/NOM (Punch/notch module)

P2 Various tools with a working pressure of 0.6

MPa

Tool Connection (port)

POT Port 4

Procedure

⇨ The tool is attached and allocated to the module

⇨Use

✓ The tool is ready for use

Tool connector

corresponding port

1-1-1-3-1-1 to allocate the tool connection to the

P4 POT

000010,10,05-2010, jmu

Zund M-1600, L-3200, L-2500, XL-3200, 2XL-1600 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Introduction

1.1 Foreword

1.2 Using the documentation

1.2.1 Structure of the operating manual

1.2.2 Symbols

1.3 Points to note when reading this operating manual

1.4 Care of the documentation

1.5 Current status of documentation

1.6 Standardisation, tests, marking

1.6.1 Standards

1.6.2 CE marking

1.6.3 UL testing

1.7 Legal notice

1.8 Troubleshooting, hints and tips

1.9 Documented cutter models

1.10 Publishing details

2 Product description

2.1 General

2.2 Product identification

2.2.1 Rating plate

2.2.2 UL marking

2.3 Intended use

2.4 Cutter - overview

2.5 Modules, tools

2.5.1 General

2.5.2 UM

2.5.2.1 Tools for the UM

2.5.3 RM-A

2.5.4 PUM

2.5.5 MAM-S/D

2.6 Material handling, options

2.6.1 Laser pointer

2.6.2 ICC camera

2.6.3 Cutter with static work surface

2.6.4 Cutter with conveyor

2.6.5 Sheet feeder options

2.6.6 Drip tray

2.7 Technical description

2.7.1 Complete machine

2.7.2 Schedule of work sequences

2.7.3 Complete machine

2.7.4 Movement system

2.7.5 Processing materials

2.8 Technical information

2.8.1 Dimensions and weights

2.8.1.1 Basic device

2.8.1.2 Cutter extension

2.8.2 Electrical connection, power consumption

2.8.3 Environmental conditions

2.8.4 Basic device compressed air

2.8.5 Control unit

2.8.6 Performance

2.8.7 Emissions

2.8.8 FCC approval

3 Safety

3.1 General

3.2 Proper use

3.3 Examples of improper use

3.4 Hazard warnings, important instructions

3.4.1 Explanation of the hazard warning

3.4.2 Structure of the hazard warnings

3.5 Areas of responsibility

3.6 Personnel requirements

3.7 Rules and safety at work

3.8 Procedure in case of malfunctions

3.9 Danger areas

3.9.1 General danger area

3.9.2 Danger area on the module carriage

3.9.3 Danger area during the installation

3.10 Working and traffic area

3.11 Safety signs

3.11.1 Responsibility of the operator

3.11.2 Position of the safety signs

3.12 Safety and monitoring devices

3.12.1 Protective system

3.12.2 Operating unit