Gerber Technology AccuPlot AP-100 User manual

AccuPlot
AP-100/AP-300/AP-520 USER’S GUIDE


   
! 
!!
"#$$%$$&'#()$!!
!! 
! *
 !!!
  !
) !
! !

!+ 
!!!
!, !!
!-!!!
./.,!&
0/11
,!,!
 !
! !&'!"
(!./ ! 

2!,3! 
 - ,3 ,
!&  
'#43#43&#"#443#3!
3!

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6&$7$5
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i
Contents
PREFACE iii
Product Documentation.............................................................................................iii
Chapter Summary................................................................................................iii
Conventions in this Guide....................................................................................iv
GGT Product Support ...............................................................................................iv
Within the United States and Canada ..................................................................iv
Outside the United States and Canada ................................................................iv
INTRODUCTION CHAPTER 1
AccuPlot AP-100 and AP-300 Series Plotters.............................................................1
AccuJet AJ-520 Plotters.............................................................................................1
Safety ........................................................................................................................2
Remember These Safety Practices.......................................................................2
Emergency Stop...................................................................................................2
Sliding Covers ......................................................................................................2
STARTING AND STOPPING THE PLOTTERS CHAPTER 2
Power On and Initialization.........................................................................................1
Power On..............................................................................................................1
Initializing the Plotter ............................................................................................2
Putting the Plotter Online...........................................................................................3
Stopping the Plotter....................................................................................................4
Offline...................................................................................................................4
Power Down..........................................................................................................4
PLOTTER HARDWARE COMPONENTS CHAPTER 3
Hardware Summary ...................................................................................................1
Main Power Panel......................................................................................................4
Paper Transport System.............................................................................................5
Carriage and Pen Assembly.......................................................................................5
Control Panel.............................................................................................................6
Table Orientation .......................................................................................................8
OFFLINE OPERATION CHAPTER 4
The Offline Menu.......................................................................................................1
Initializing the Plotter..................................................................................................3
Putting the Plotter Online...........................................................................................3
Advancing the Paper..................................................................................................4
Reversing the Take-up Roll........................................................................................5
Setting the Origin.......................................................................................................6
Raising and Lowering the Pen....................................................................................7

ii
OFFLINE OPERATION (Cont’d) CHAPTER 4
Disabling and Enabling Servo Power.........................................................................8
Resetting the Plotter........................................................................................... 10
Plotter Parameters................................................................................................... 11
Changing Plotter Parameters..............................................................................12
Saving Parameters.............................................................................................19
Loading Default Parameters...............................................................................20
Setting the Pen and Inkjet Timers............................................................................21
Downloading Firmware............................................................................................23
Diagnostic Tests...................................................................................................... 26
ACCUPLOT AND ACCUJET MAINTENANCE CHAPTER 5
Plotter Supplies .........................................................................................................1
Routine Cleaning.......................................................................................................2
Loading Plotter Paper................................................................................................3
To Load A New AJ-520 Supply Roll......................................................................4
Load New AccuJet Take-up Roll...........................................................................7
Loading Paper on the AP-100/AP-300..................................................................9
Switching to the Second Paper Roll....................................................................12
Using Paper Width Adapters ..............................................................................13
Plotter Pen Maintenance..........................................................................................14
Task overview....................................................................................................14
AJ-520 Pen Maintenance ...................................................................................15
AccuPlot Longlife Pen Maintenance ................................................................... 18
GLOSSARY G-1
INDEX I-1
List of Figures
Figure 3-1 Top view of the AP-320......................................................................3-2
Figure 3-2 Top view of the AccuJet 520 ..............................................................3-3
Figure 3-3 AccuPlot 100/300 Power Panel...........................................................3-4
Figure 3-4 AccuJet 520 Power Panel...................................................................3-4
Figure 3-5 AJ-520 dancer bar..............................................................................3-5
Figure 3-6 Control panel assembly......................................................................3-6
Figure 3-7 X-axis, Y-axis, and GGT default origin................................................3-8
Figure 4-1 Plotter Menu Structure........................................................................4-2
Figure 4-2 Plotter Diagnostics Menu..................................................................4-27
Figure 5-1 AJ-520 Longlife Pen Assembly.........................................................5-15
Figure 5-2 AccuPlot Longlife Pen & Ink Reservoir.............................................5-19

iii
Preface
AccuJet™ and AccuPlot™ is an optional plotting device used with the AccuMark™ ,
MicroMark™, and AccuMark Silhouette™ systems.
Product Documentation
This Operator’s Guide is intended to be used by the person responsible for day-to-day
plotting operations and for the person responsible for the plotter’s routine
maintenance. This document includes operating instructions for the AccuJet AJ-520
plotter as well as the AccuPlot AP-100 and AP-300 series of plotters.
Chapter Summary
Topics covered include plotter functions, default operating parameters, and routine
maintenance guidelines. The guide is organized into the following chapters:
1. Introduction This chapter covers AccuPlot and AccuJet safety procedures.
2. Starting and Stopping Plotters This chapter describes how to turn on and
turn off the AccuPlot and AccuJet plotters.
3. Plotter Hardware Components This chapter is provided to help identify
the parts of the plotters referenced in this document. This chapter also tells
you how to turn the plotter on, how to put the plotter online, and how to
turn the plotter off.
4. Offline Operation This chapter covers the Offline menu structure and
offline plotter operations, with an emphasis on plotter commands and
functions.
5. AccuPlot and AccuJet Maintenance This chapter describes maintenance
procedures required to keep your AccuJet or AccuPlot plotters operating at
maximum efficiency and accuracy.

iv
Conventions in this Guide
The following conventions are used throughout this guide:
WARNING: WARNINGS ALERT YOU TO CONDITIONS THAT CAN CAUSE INJURY TO
YOU OR CAUSE DAMAGE TO THE EQUIPMENT.
DO NOT IGNORE WARNINGS.
This type of heading indicates the beginning of a procedure.
Procedure steps are numbered and should be followed in the order presented.
Always read the entire procedure before beginning, to be sure you understand the
steps, have all necessary tools or supplies, and are aware of any warnings.
GGT Product Support
As part of our commitment to excellence, GGT® provides complete worldwide support
for the AccuJet and AccuPlot plotters.
Within the United States and Canada
For service support within the US and Canada, call 1-800-321-2448. For information
about training or about other GGT products, call your local GGT Sales and Service
Office.
Outside the United States and Canada
For service support, information about training, or information about other GGT
products outside the US and Canada, call your local GGT Sales and Service Office.

Introduction 1-1
AccuPlotAccuPlot APAP-100 and AP-100 and AP-300 Series Plotters-300 Series Plotters
AccuPlot plotters are designed to plot markers and pieces, either full-size or in
miniature. Working with your marking and grading system, these plotters draw
individual pieces or markers on paper for verification of piece accuracy, or for
later use in cutting fabric.
The models that make up the series are the AP-100, the AP-110, the AP-300,
the AP-310/320 and the AP-350/360. The AP-100 and AP-300 use a different
paper transport method and a smaller diameter paper roll than the other
plotter models.
The only difference between the AP-320 and AP-360 models is the maximum
paper width that can be used:
• AP-310/320 2000 millimeters (78.7 inches)
• AP-350/360 2400 millimeters (94.5 inches)
AccuJet AJAccuJet AJ-520 Plotter-520 Plotter
The GGT AccuJet 520 plotter combines the speed and quality of pen plotting
of pattern outlines with the throughput and efficiency of inkjet printing for
annotation.
Annotation is printed at speeds up to 635 mm per second (25 ips) and can be
placed at any angle.
The AccuJet 520 plotter works with your marking and grading system.
IntroductionIntroduction
11

Introduction
1-2Safety
SafetySafety
Every effort has been made to design safety into AccuPlot and AccuJet plotters.
• Edges are rounded to eliminate pinch points.
• Electronic components are enclosed.
• Emergency Stop (E-Stop) push buttons are easily reached.
In addition, control programs include safety functions which automatically
stop operation under certain error conditions.
Remember These Safety PracticesRemember These Safety Practices
• Use extreme caution when reaching under the carriage or beam.
• When a plotter is networked, jobs can be sent to the plotter from any
system on the network. Do not assume the system will not begin
operating simply because you are not sending work.
• Stay out of the path of the beam at all times.
• Do not perform any maintenance on the plotter while the servos are
enabled.
• Do not access the electrical panels while power is applied.
Emergency StopEmergency Stop
The emergency stop switch is a red, push/twist switch that turns the plotter on
and off. The switch is located in the lower right corner of the control panel.
Twisting the emergency power switch in the direction of the marked arrows
allows the plotter to be powered on. Pushing the switch down turns the power
off and immediately stops the beam and carriage assemblies.
NoteNote: In an emergency, push the emergency power switch down. This stops the
beam and carriage instantly.
Sliding CoversSliding Covers
The AccuJet 520 is equipped with covers which help prevent injury to
operators or damage to the AccuJet during plotter operation. The sliding
covers should be closed before operating the plotter.

Power On and Initialization 2-1
The plotter must be online before it can accept and process data from your
marking and grading system. Before the plotter can be put online, power must
be applied and the plotter must be initialized.
The following are the procedures for starting, initializing, and putting the
plotter online. Read all the steps before beginning a procedure to be sure you
understand the process.
Power On and InitializationPower On and Initialization
The system must be initialized if power has been turned off or after an
Emergency Stop (E-Stop) is detected. Initializing clears the system’s memory
buffer and positions the head at the origin (starting) position.
NOTE: Before turning the system on, be sure the table surface and surrounding area
are clear of obstructions.
Power On
1. Be sure all plugs and connectors are in place and all safety features are in
place.
2. Switch the plotter main power to ON.
3. Turn the emergency stop switch in the direction of the arrows until it
unlocks and pops up. The plotter performs a self-test and then displays the
following system prompt:
Starting and Stopping the PlottersStarting and Stopping the Plotters
22
PLOTTER MODEL V X.X.X
Press enter to
enable the plotter.

Starting and Stopping the Plotters
2-2Power On and Initialization
4. Press Enter to display page one of the Offline menu.
Initializing the Plotter
Initializing clears the plotter memory buffer and positions the pen assembly at
the origin (starting) position. Initializing also loads the operating parameters
currently defined for the plotter.
You must initialize the plotter after turning the power on and after any
emergency stop.
TO INITIALIZE THE PLOTTER
1. From page one of the Offline menu, press F2-INITIALIZE. To interrupt the
process, press F3-STOP.
2. Once initialization is complete, page one of the Offline menu appears in
the control panel window again.
OFFLINE . . .
ONLINE PAPER ADV
INITIALIZE ORIGIN
OFFLINE . . .
ONLINE PAPER ADV
INITIALIZE ORIGIN
INITIALIZING . . .
STOP

Starting and Stopping the Plotters
Putting the Plotter Online 2-3
Putting the Plotter OnlinePutting the Plotter Online
Online means the plotter is ready to process jobs from the plot queue as soon
as they are received. As a safety measure the system prompts you to confirm
setting the system online. Offline is a type of standby mode. Although certain
plotter components can be operated manually when offline, the system cannot
perform plot jobs sent to it.
WARNING FAILURE TO KEEP HANDS AND CLOTHING AWAY FROM THE
PLOTTING AREA WHEN THE PLOTTER IS ONLINE MAY
RESULT IN INJURY.
On a network, jobs can be sent to the plotter from any system on the network.
Do not assume the system will not begin operating simply because you are not
sending work.
When online, the plotter will begin operating as soon as it receives data. Stay
out of the path of the beam when the system is online.
TO PUT THE PLOTTER ONLINE
1. Power on and initialize the plotter.
2. Press F1-ONLINE.
The plotter is now online with the marking and grading system and is
ready to receive data. If you have already sent data, the plotter begins
to plot.
ONLINE
OFFLINE

Starting and Stopping the Plotters
2-4Stopping the Plotter
Stopping the PlotterStopping the Plotter
You can stop plotter operation by pushing an E-Stop button, taking the plotter
offline, or by shutting off the power.
When the plotter is taken offline, data for jobs in process is retained. If,
however, you turn the plotter power off while it is plotting, plot data is lost.
Offline
TO TAKE THE PLOTTER OFFLINE
1. From the ONLINE display, press F3-OFFLINE.
NOTE: Do not move the pen assembly or delete the job from the Plot Queue while the
plotter is stopped.
Power Down
TO SHUTDOWN THE PLOTTER
1. From the ONLINE display, press F3-OFFLINE.
2. Push down on the emergency stop switch until it disengages.
3. Set the main power switch to OFF.

Hardware Summary 3-1
This chapter describes the basic physical attributes of the AccuJet and
AccuPlot 100/300 plotter families. Illustrations are included to help you
identify the components that are referenced in procedures. Before operating
any plotter or performing any maintenance, be sure you are familiar with its
hardware and safety features.
Hardware SummaryHardware Summary
All of the plotters discussed in this guide provide cable driven, X-Y plotting.
The beam moves on the Y-axis. All except the AP-100 and AP-300 models
allow single sheet offloading. Table 3-1 summarizes the physical
characteristics of each model.
Table 3-1Plotter Physical Characteristics Summary
Model Pen Type Plot Width Roll Diameter Single Sheet Offloading Carriage Cabling Footprint Reverse Paper
Take-up
AP-100 disposable 1550 mm
(61.0 in.) 165 mm (6.5 in.) no whip 915 x 2090 mm (36 x 83 in.) no
AP-110 disposable 1550 mm
(61.0 in.) 241mm (9.5 in.) yes whip 915 x 2090 mm (36 x 83 in.) no
AP-300 disposable 2000 mm
(78.7 in.) 165 mm (6.5 in.) no whip 915 x 2667 mm (36 x 105 in.) no
AP-310 disposable
cartridge 2000 mm (78.7 in.) 241mm (9.5 in.) yes whipless 915 x 2667 mm (36 x 105 in.) no
AP-320 disposable
cartridge 2000 mm (78.7 in.) 241mm (9.5 in.) yes whipless 915 x 2667 mm (36 x 105 in.) yes
AP-350 disposable
cartridge 2400 mm (94.5 in.) 241mm (9.5 in.) yes whipless 915 x 3035 mm (36 x 119.5 in.) no
AP-360 disposable
cartridge 2400 mm (94.5 in.) 241mm (9.5 in.) yes whipless 915 x 3035 mm (36 x 119.5in.) yes
AP-520 longlife
(refillable
reservoir)
2000 mm
(78.7 in.) 241mm (9.5 in.) yes whipless 915 x 2667 mm (36 x 105 in.) yes
Figure 3-1 illustrates major components of the AP-100/AP-300 series plotters.
Figure 3-2 illustrates major components of the AccuJet AJ-520 plotter.
Plotter Hardware ComponentsPlotter Hardware Components
33

Plotter Hardware Components
3-2Hardware Summary
Note:Note: All locations assume that you are standing at and facing the control panel.
Figure 3-1Top view of the AP-320
Paper Take-up Roll
Drive Roller
Pinch Roller
Carriage/
Pen Assembly
Supply Roll
Beam
Control Panel
Power Switch
Right Side

Plotter Hardware Components
Hardware Summary 3-3
Note:Note: All locations assume that you are standing at and facing the control panel.
Figure 3-2Top view of the AccuJet 520
Drive Roller with
independent Grippers
Carriage Assembly
contains the Long-Life Pen
and the Inkjet Assemblies
Control Panel with
Emergency Stop Switch
Power on/off switch
located just above
paper supply roll.
Data connector is
located left of the
power switch.
Paper supply roll
Dancer bar is
located under the
paper supply roll.
Beam
table with
sliding covers
Right Side
Linear Bearing

Plotter Hardware Components
3-4Main Power Panel
Main Power PanelMain Power Panel
The main power panels includes the on/off switch and data connectors.
Figures 3-3 and 3-4 show the power panels for the AccuPlot and the AccuJet
plotters.
Line Power
Main Power Switch
Computer
Far end of the paper roll
Figure 3-3AccuPlot 100/300 Power Panel
Computer
Far end of the supply roll.
Line Power
Main Power Switch
Figure 3-4AccuJet 520 Power Panel

Plotter Hardware Components
Paper Transport System 3-5
Paper Transport SystemPaper Transport System
New paper is loaded on the PAPER SUPPLY ROLL. Paper is fed from the supply
roll, across the table surface to the DRIVE ROLLER. On the AccuJet 520 a DANCER
BAR is positioned across the width of the paper between the supply roll and
the AccuJet table (Figure 3-5). The dancer bar provides even tension across the
supply paper, resulting in more accurate plots.
dancer bar
to table
supply roll
Figure 3-5AJ-520 dancer bar
The drive roller advances the paper during a page advance.
All AccuPlot plotters except the AP-100 and AP-300 include a PINCH ROLLER,
which holds the paper onto the drive roller during page advances. On the
AccuJet 520, individual GRIPPERS perform the same function. The pinch
roller/grippers must be in contact with the paper to avoid a misfeed.
Used paper is collected on the TAKE-UP ROLL.
Carriage and Pen AssemblyCarriage and Pen Assembly
The carriage, mounted on the beam, moves the pen assembly along the X-axis.
The AP-100 and AP-300 plotters use disposable pens. The AP-310/320 and
AP-350/360 use disposable cartridges. AccuJet 520 plotters use a long-life pen
assembly with a refillable ink reservoir. The AJ-520 inkjet assembly, which is
mounted on the same carriage as the pen assembly, holds the inkjet cartridge
used to draw annotation. The inkjet assembly rotates, which allows annotation
to be placed at any angle.

Plotter Hardware Components
3-6Control Panel
Control PanelControl Panel
The control panel provides easy access to plotter operational functions and
diagnostic tools. Chapter 4, Offline Operation, explains the plotter functions
available.
All AccuPlot and AccuJet functions are available from control panel menus.
The control panel design, shown in Figure 3-6, is the same for both families of
plotters.
F1
F2
F3
F4
1
2
Arrow Keys Function Keys
F1 – F4
Menu Key
Enter Key
Display Window
Emergency Stop
Figure 3-6Control panel assembly
Emergency Stop The switch is located in the lower right corner of the
control panel. Twisting the emergency power switch in
the direction of the marked arrows allows the plotter to
be powered on. Pushing the switch down turns the
power off and immediately stops the beam and carriage
assemblies.

Plotter Hardware Components
Control Panel 3-7
Display Window Plotter status messages, menu choices, and system
prompts appear in this window.
Arrow Keys The arrow keys are used to move the pen assembly
around the table when the plotter is offline, and to
move the cursor during certain menu functions. Each
arrow key is marked indicating the direction the pen (or
cursor) will travel when the arrow key is pressed.
Function Keys To choose from a menu or to respond to a prompt,
press the function key associated with your choice or
response.
F1
F2
F3
F4
Lines indicate
which function
key controls
which option
displayed on
the screen. F1 function F3 function
F2 function F4 function
Menu Key Several of the plotter menus have multiple layers, called
pages. The Menu key allows you to move from page to
page.
Enter Key The Enter key is marked by a dot in the center. The
Enter key is also used to select menu options, register
parameter changes and, in some functions, to signal the
plotter to begin a process.
1
2

Plotter Hardware Components
3-8Table Orientation
Table OrientationTable Orientation
Some procedures in this guide refer to the X-axis, the Y-axis, or the origin
point. Figure 3-7 shows each axis direction and the GGT default origin.
Figure 3-7X–axis, Y–axis, and GGT default origin
Y–axis
X–axis
0,0
GGT default origin