Gerber Sabre User manual

P66441A Rev A

Copyright Notice
COPYRIGHT1997 Gerber Scientific Products, Inc. All Rights Reserved.
This document may not be reproduced by any means, in whole or in part, without written permission
of the copyright owner.
This document is furnished to support the Mist Coolant Option. In consideration of the furnishing of
the information contained in this document, the party to whom it is given assumes its custody and
control and agrees to the following:
1. The information herein contained is given in confidence, and any part thereof shall not be
copied or reproduced without written consent of Gerber Scientific Products, Inc.
2. This document or the contents herein under no circumstances shall be used in the manufacture
or reproduction of the article shown and the delivery of this document shall not constitute any
right or license to do so.
Printed in USA
Sabre is a trademark of Gerber Scientific Products, Inc. TRIM is a registered trademark of Master Chemical
Corporation.

Contents
Welcome ...................................................................................................................................... 1
About this booklet........................................................................................................................ 1
Getting help.................................................................................................................................. 1
Kit contents .................................................................................................................................. 1
Installing the Mist Coolant Option............................................................................................... 2
Installing the coolant control panel.......................................................................................... 2
Installing the hoses in the cable carrier.................................................................................... 2
Mounting the coolant tank .......................................................................................................4
Assembling the coolant tank .................................................................................................... 4
Filling the coolant tank................................................................................................................. 5
Using mist coolant........................................................................................................................ 6
Turning off mist coolant............................................................................................................... 7

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Welcome
Thank you for purchasing the Mist Coolant Option for your Sabrerouter. This
option sprays a fine lubricant mist on the cutting tool to cool and lubricate it
when cutting metals such as aluminum and brass. You do not use it when cutting
non-metallic materials such as wood or plastic.
About this booklet
This booklet provides a list of the kit contents and instructions for installing and
using the Mist Coolant Option. Special information in this booklet is presented
in notes, cautions, and warnings as follows:
T
Note: A note contains important information which could affect successful
completion of a task.
T
CAUTION: A caution statement contains information which, if not
observed, could result in damage to the equipment.
T
WARNING: A warning statement contains information which, if not
observed, could result in personal injury.
Getting help
If you have questions regarding the installation or use of the Mist Coolant
Option, please contact the Gerber Router Support Group at:
860-528-1028
860-290-5568 (fax)
Kit contents
The Mist Coolant Option kit contains the following:
T coolant control panel with flex lines and attaching hardware
T coolant tank kit with filter, cap plug, retainer and attaching hardware
T 1 tie wrap
T 1 gallon of TRIMmist coolant
T flex line support bracket with mounting screw and washer

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Installing the Mist Coolant Option
Installing the Mist Coolant Option involves the following steps:
T
Install the coolant control panel on the carriage.
T
Feed the coolant hoses through the cable carrier behind the beam.
T
Mount the coolant tank
T
Assemble the coolant tank
Note: You must have a source of continuous compressed air between 90 psi
minimum and 120 psi maximum.
Installing the coolant control panel
1. Attach the coolant
control panel to the
right side of the motor
carriage using two
M4 screws and lock
washers provided in
the kit. Insert the
screws into the center
holes of the control
panel and tighten.
2. Attach the control
panel cover using the
four M4 screws
provided in the kit.
Installing the hoses in the cable carrier
1. The two hoses are surrounded by a large black hose for the first several feet
as they first come out of the coolant control panel. After they come out of
the large black hose, tape the two hoses together to make them easier to feed
through the cable carrier. Tape the ends as well as several places along the
hose.
2. Move the motor carriage all the way to the front left corner of the table.
3. Position the coolant hoses so that they pass over the top of the chip removal
hose.

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4. Feed the mist coolant hoses through the cable carrier until the ends of the
hoses reach the bend in the cable carrier.
5. Move the carriage to the front right corner of the table.
6. Pull the hoses out of the cable carrier, then feed them back into the carrier
through the same slot. Pulling them out first makes feeding them through the
remaining section of the carrier easier.
7. Continue to feed the hoses until they reach the end of the carrier. Gently pull
the slack out of the hoses.
8. At the left side of the carrier, position the black hose surrounding the
coolant hoses so that it can be tie-wrapped to a tie wrap mounting tab.
Attach it to the tab.
9. Feed the mist coolant hoses through the tie wraps on the chip removal hose.

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Mounting the coolant tank
1. Remove the fill hole cap
from the tank top.
Remove the two tank top
screws attaching the top to
the reservoir, then remove
the top.
Remove the two lower left
beam end plate screws
shown at the right.
Attach the tank reservoir
and bracket to the left end
of the beam with the screws
removed at step 3.
Assembling the coolant tank
1. Feed the hoses through the small hole in
the tank top.
2. Push the blue hose (the air hose) onto the
barb as shown in the illustration at the
right.
Note: You may need to trim excess hose
so that it fits comfortably within the
enclosure.
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3. Feed the black hose with the red stripe
(coolant hose) through the yellow cap
supplied in the kit as shown in the
illustration.
4. Attach the filter supplied in the kit to the
end of the hose and feed it through the
hole in the top of the tank reservoir until
it rests on the bottom of the tank.
5. Press the yellow cap into the hole in the
top of the tank reservoir.
6. Replace the tank top and secure it to the
reservoir with the two hex screws.
7. Replace the fill hole cap.
8. Screw a compressed air quick disconnect fitting to the outside of the tank
top opposite of where you attached the blue air hose over the barb on the
inside. Seal the threaded connection with teflon tape.
Filling the coolant tank
TRIM mist coolant is a vegetable-based liquid which can skin over or clot if left
in the coolant tank for awhile. This can create restrictions in the liquid tubing,
the nozzle tips, and the pickup filter and tube. Do not mix more than you are
likely to use for a job.
1. Prepare the coolant mixture by mixing water and coolant in a 10-to-1 ratio.
You must use only TRIM mist coolant with the Trico mist system.
2. Remove the fill hole cap and pour the coolant mixture into the tank. Do not
overfill.
If you do not use all the mixture, empty any leftover mixture into a separate,
covered container. Put about a cup of plain warm water in the tank and open the
air and coolant valves as described in the next paragraph to rinse out the system.
Leftover coolant mixture can be reused. Just skim off any skin on the top of the
mixture and pour it into the coolant tank.
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Using mist coolant
Note: The Mist Coolant Option cannot be used at the same time as the Chip
Removal System or the Engraving Option.
1. Disconnect the chip removal system vacuum hose from the vacuum shroud
and tuck it behind the motor carriage.
2. Remove the pressure foot and vacuum shroud from the carriage by
removing two screws from each side of the shroud. Store the screws with the
shroud.
3. Attach the flex line support
bracket to the lower right
vacuum shroud hole in the
carriage using an M6 X 16
socket screw and washer
supplied in the kit.
CAUTION: When uncoiling
and coiling the flex lines, do
not twist them or you may
kink the hoses within the
lines. To unkink hoses, pop
the flex line segments apart
one at a time until you locate
the kink, then reconnect the
line segments.
4. Carefully uncoil the flex lines.
5. Attach the upper flex line (Line
1) to the left clamp. Attach the
lower flex line (Line 2) to the
right clamp.
6. Position the tips at right angles
to each other, aimed at the point
where the tool will enter the
material being cut, and pointing
slightly down and forward. Do
not aim the tips pointing
toward the rear of the router
table −coolant can be sprayed
on the carriage lead screw
and damage it.
7. Use the quick disconnect plug to connect the compressed air hose to the
coolant tank and turn on the compressed air.

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8. Remove the fill hole cap and check the coolant level before starting each
job. Refill the tank, if necessary.
9. Open both air valves by turning the control knobs one-quarter turn
counterclockwise until you hear the air come out of the tips.
10. Open both coolant valves by turning the control knobs one-quarter turn
counterclockwise until coolant starts to come out.
Note: Because the coolant fluid is siphoned into the hoses, coolant may not
appear at the nozzles for approximately 45 seconds after the valves have
been opened for the first time. After you have used mist coolant the first
time, coolant may not appear for 10 to 15 seconds.
11. Adjust the amount of spray by adjusting both the coolant and air valves until
a wet mist is sprayed on the material. Light spray is appropriate for most
jobs. Use heavier spray for soft materials. If the amount of spray is
insufficient, the material will overheat and may melt, and tools may break.
12. Start the job. Check the material for correct coolant delivery and adjust as
necessary during the job. Keep the material wet, but do not allow the
coolant to puddle on the material.
Note: If the mist stops, check the following:
T
the nozzle tips may be clogged
T
no coolant in the tank
T
the flex lines may be twisted
T
the air pressure may not be high enough
Turning off mist coolant
After the job has completed, turn off the coolant valves first, then turn off the air
valves. Turning off the valves in this sequence keeps coolant in the hoses and
speeds delivery when the system is used next.
Coil the flex lines against the coolant control panel when not in use.