Gerber DCS 1500 Parts list manual

Started
Getting Manual
Manual de Inicio
入门手册

DCS 1500™/DCS 2500™
GERBERcutter®
Getting Started Manual

Page iii
English
Copyright Notice
Copyright © 2008 – 2018 by Gerber Technology LLC. All rights
reserved. This document may not be reproduced by any means, in whole
or in part, without the written permission of the copyright owner. This
document is part of the proprietary articles furnished to document the
DCS 1500™/DCS 2500™ GERBERcutter® cutting systems.
In consideration of the furnishing of the information contained in this
document, the party to whom it is given assumes control and custody and
agrees to the following:
¨The information contained herein is given in confidence and any part
thereof shall not be copied or reproduced without the written consent
of Gerber Technology LLC.
¨This document, or the contents herein, under no circumstances shall
be used in the manufacture or reproduction of the articles shown, and
the delivery shall not constitute any right or license to do so.
The information in this document is subject to change without notice.
Gerber Technology LLC, and its subsidiaries and affiliates, shall not be
liable for errors in this documentation, for incidental or consequential
damages in connection with furnishing, for use of this material including,
for example, loss of profits, fabric, and production time. AccuMark®,
CutWorks®, and GERBERcutter® are registered trademarks of Gerber
Technology LLC. MicroMark™, DCS 1500™, and DCS 2500™ are
trademarks of Gerber Technology LLC, in the United States, all rights
reserved. Other company names, brand names, and product names
mentioned in this book are trademarks or registered trademarks of their
respective companies.
Corporate Headquarters
Gerber Technology LLC
24 Industrial Park Road West
Tolland, CT 06084 USA
Telephone [phone]

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Revision History
Date Revision Author Changes
09/2008
B
N/A
Original
02/2018
C
SB
Rebranded entre document.
Reformatted English and
Chinese. Replaced Spanish
translation.

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Table of Contents
COPYRIGHT NOTICE .............................................................................. 1
INTRODUCTION .................................................................................... 1
FEATURES ............................................................................................. 1
CUSTOMER SUPPORT ........................................................................... 1
CUSTOMER SOLUTION CENTERS ................................................................... 2
ADVANCED TECHNOLOGY CENTERS............................................................... 2
SAFETY INSTRUCTIONS ......................................................................... 3
SAFETY LABELS.......................................................................................... 3
WARNINGS AND CAUTIONS ......................................................................... 5
DANGEROUS PROCEDURES.......................................................................... 5
EQUIPMENT TRAINING ............................................................................... 6
DO NO MAINTENANCE ALONE..................................................................... 6
ENERGIZED CIRCUITS.................................................................................. 6
DE-ENERGIZE CUTTER BEFORE MAINTENANCE AND INACTIVITY .......................... 7
COMPRESSED AIR...................................................................................... 7
DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE........................................... 7
MOVING MACHINERY ................................................................................ 7
REPLACING PARTS ..................................................................................... 7
LASER LIGHT............................................................................................. 7
CLOTHING................................................................................................ 8
CUTTING TOOLS ........................................................................................ 8
WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) .................. 8
SYSTEM DESCRIPTION .......................................................................... 9
LOCAL AND ONLINE MODES ........................................................................ 9
HARDWARE OVERVIEW ........................................................................ 9
HARDWARE DESCRIPTION .................................................................. 11
(1) EMERGENCY STOP (E-STOP)SWITCHES AND (2) E- STOP BUMPER ARMS ..... 11
(2A)E-STOP RECOVERY PROCEDURE........................................................... 13

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(3) BEAM CONTROL PANEL (BCP) .............................................................. 13
(3A)KEYPAD........................................................................................... 15
(3B)ENTERING AND EXITING LOCAL AND ONLINE MODES ............................... 16
(3C)JOYSTICK ......................................................................................... 17
(4) CONTROL DESK .................................................................................. 17
(5) CUTTER HEAD AND (6) BEAM......................................................... 20
(7) FESTOON-SIDE COVER ................................................................... 21
(8) TABLE SURFACE AND (9) VACUUM (UNDER TABLE) ....................... 22
(10) VACUUM VALVES (DCS 2500 ONLY) ............................................. 23
(11) VACUUM STARTER BOX – VACUUM ON/OFF ............................... 24
CUTTING TOOLS .................................................................................. 25
TOOL HOLDERS ................................................................................... 26
CUTTING TOOL INSTALLATION ............................................................ 27
KNIFE CUTTER CALIBRATION PROCEDURE........................................... 28
OPERATING THE DCS 1500/2500 GERBERCUTTER ............................... 32
BASIC CONCEPTS ..................................................................................... 32
DATA PREPARATION................................................................................. 32
VACUUM HOLD DOWN............................................................................. 33
KNIFE SHARPNESS .................................................................................... 33
MOTION CONTROL .................................................................................. 34
COMPLETE A CUT ................................................................................ 34
GLOSSARY........................................................................................... 45
APPENDIX ........................................................................................... 49
DCS 2500 OPTIONS ................................................................................ 49
CONSUMABLES AND TOOLS........................................................................ 50
CUTTER SPECIFICATIONS............................................................................ 52

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Introduction
The DCS1500/2500 GERBERcutter® systems are high-speed, single- or
low-ply, static table cutting systems. They are designed to cut a wide
variety of materials and fabrics, and easily cut cloth, composites, leather,
industrial fabrics, and most other rolled goods for use in apparel,
furniture, automotive, aerospace, and other industries.
Features
The DCS 1500™/2500™ GERBERcutter systems have the following
standard features:
¨Windows-based operating system.
¨Multiple tool mounts for up to three tools and a pen for plotting and
annotation.
¨Pneumatic system permits adjustment of pen and cutter downforce.
¨Split table operation for different applications on either side of table.
¨Self-contained cutting table with a vacuum system that includes a
porous table surface for maximum fabric hold-down capability.
¨Automatic preprocessing includes all program editing functions,
including toolpath optimization.
Customer Support
Contact the Gerber Regional Customer Solution Center with support or
technical questions.
When calling, fill in the following information and have it available for
support:
Center phone number _________________________
Sales order number _________________________

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Purchase date _________________________
Product name and type _________________________
Optional equipment used _________________________
Software _________________________
(include version)
Description of problems and the exact wording of any computer error
messages.
Customer Solution Centers
Gerber’s worldwide Customer Solution Centers are staffed by multi-
lingual, trained experts at all hours. To find a local Customer Solution
Center, visit www.gerbertechnology.com.
Advanced Technology Centers
Gerber's Advanced Technology Centers are dynamic hubs for product
demonstrations, software testing, system training, engineering, and R&D
activities.
North America
Phone: [phone] (toll free in USA)
1.866.796.8570 (Spanish language)
China
Phone: [phone]
Europe
Phone: [phone]

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Safety Instructions
Read and understand all safety instructions before operating the
equipment to prevent personal injury, death, or equipment damage.
Safety Labels
These safety labels are located at various parts of the equipment,
including the cutter head, beam, and electrical components.
Symbol Description
Electrical ground to frame.
Earth ground.
Frame or chassis ground.
Earth (ground) terminal.
Emergency stop (E-Stop).

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Symbol Description
Electrical shock potential.
Friction hazard.
Moving member.
Pinch point.
Hand crush force from above.
Danger: Moving parts can crush and cut.
Warning: To avoid injury, read and
understand the getting started manual
before using this machine.

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Symbol Description
Warning: Read and understand the getting
started manual before using this machine.
Caution: Hot surface. Do not touch.
(Vacuum exhaust and silencer surfaces
may be hot.)
Warning: Avoid direct eye exposure with
the laser light beam.
Figure 1: Safety labels
Warnings and Cautions
Warnings and cautions precede some steps or procedures. Always follow
these precautions to prevent personal injury or equipment damage.
¨Warnings are put before procedures that could result in personal
injury, death, or equipment damage.
¨Cautions are put before procedures that could result in equipment
damage.
Dangerous Procedures
Always follow warnings and cautions. Follow all other necessary safety
instructions to ensure safe equipment operation in its operating location.
¨Password protection is available to protect against unauthorized use
of equipment.

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¨Do not attempt to move or interfere with material during cutting
operation.
¨Never leave the system unattended during cutting operation.
¨Before performing maintenance on the pneumatic system or parts
moved by the pneumatic cylinders, disconnect the cutter from the
factory air supply.
¨Do not energize the system when cables, printed circuit boards, or
both are disconnected.
¨Do not operate the cutter with the cover of any enclosure or the guard
covers over any mechanism removed.
¨Do not cut any material or operate the cutter in any manner other
than for the purpose that it was designed and sold without prior
consultation with Gerber Technology.
Equipment Training
Operate this machine only after approved training.
Do No Maintenance Alone
Do not perform equipment maintenance alone. Make sure another person
is present who can administer emergency first aid.
Energized Circuits
High voltages are inside the vacuum enclosure, electric panel and
electronics control box. There are no serviceable parts inside these
covers.
Circuits must be de-energized before trained maintenance personnel can
safely work inside these areas. There must be a main switch to de-
energize each power supply that is compatible with local electrical codes.

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De-Energize Cutter before Maintenance and
Inactivity
This cutter has more than one connection to
the supply source. To reduce the risk of
electrical shock, disconnect all such
connections before servicing.
Before performing maintenance and periods of inactivity, turn off both
the Main Power switch and the Vacuum Breaker switch.
Compressed Air
Do not use compressed air to remove lint and dust from clothing or skin.
Failure to comply could result in personal injury.
Do Not Operate in an Explosive Atmosphere
Use caution when handling flammable liquids such as cleaning solvents.
Do not operate the cutter near flammable gases or fumes.
Moving Machinery
Keep hands away from all moving machine parts to prevent personal
injury. Make sure no one else is near the machine during operation.
Replacing Parts
Notify a Gerber Field Service Representative of any broken or missing
parts. Do not use parts or modifications that are not approved by Gerber
Technology. Equipment damage or personal injury could result.
Laser Light
The laser light (origin light) points at the cutting surface. It is a Class IIIr
laser product with a peak power of 5 mW at a wavelength of 670 nm. Use
of controls, adjustments or performance of procedures not in this manual
may result in hazardous radiation exposure.

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Warning: Do not look directly into the laser light source
as temporary or permanent eye damage may
result. Direct, bright reflections from the laser
may also cause eye damage. Remove
reflective material (such as jewelry and
mirrors) from the conveyor surface before
energizing the laser light.
Clothing
Do not wear loose clothing, neck chains, neckties, jewelry or long hair
near the machine. Failure to comply could result in personal injury.
Cutting Tools
Use only Gerber-supplied cutting tools.
Be sure all tools are correctly installed on the
equipment and properly mapped in the
CutWorks software. Failure to do so may result
in equipment or material damage.
Waste Electrical and Electronic Equipment
(WEEE)
All Gerber equipment is labeled as required by the Waste Electrical and
Electronic Equipment (WEEE) Directive 2002/96/EC for products placed
on the market after August 13, 2005. The WEEE Directive mandates the
collection and treatment of electrical and electronic equipment at end of
life. Refer to the Directive’s specific regional requirements.
Figure 2: WEEE compliance

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System Description
The DCS 1500/2500 GERBERcutter systems consist of a table surface
with vacuum and operator controls. The DCS 1500/2500 process cut files,
or markers, created on software such as AccuMark and CutWorks
Designer. The markers are processed using a computer and CutWorks
software.
Local and Online Modes
The DCS 1500/2500 function in two modes: Local and Online.
¨Local mode allows the operator to manually control hardware
functions, such as moving the cutter head and beam. Jogging mode is
accessed through local mode and allows the operator to move the
cutter head and beam.
¨Online mode is the default mode when the cutter is first turned on
and after a system reset. This mode processes cut files.
See Entering and Exiting Local and Online Modes for instructions.
Hardware Overview
The cutter parts shown in Figure 1 are described in more detail in the
Hardware Description section.

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Figure 3: GERBERcutter overview
ID
Component

E-Stop switch

E-Stop bumper arm

Beam control panel (BCP)

Control desk (typical location – not supplied by Gerber)
with control box

Cutter head

Beam

Festoon-side cover

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ID
Component

Table surface

Vacuum (under table)

Vacuum valves (DCS 2500 only - locations vary)

Vacuum starter box (typical location)
Hardware Description
(1) Emergency Stop (E-Stop) Switches and (2) E-
Stop Bumper Arms
Two red E-Stop switches (see Figure 2) and four yellow E-Stop bumper
arms (see Figure 3) are located on the cutter. An additional E- Stop
switch is located on the control box.
The E-Stop function should be used when there is danger to people, the
cutter, or the cut material.
This function is activated when:
¨Any of the two red E-Stop switches are pushed.
¨Any of the four yellow E-Stop bumper arms come into contact with a
person or object.
This function immediately shuts the system down. It stops all motors,
deactivates all tools, and removes all servo power supplies. It also stops
all motion.
Only the computer is energized after an E-Stop. Data is saved and an E-
Stop recovery procedure must be completed before using the cutter again.
See E-Stop recovery procedure.

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Figure 4: E-Stop switch
Figure 5: E-Stop bumper arms and switch (festoon side)
ID Component

E-Stop bumper arm

E-Stop switch