Wizard MatDesigner 5000 Series Installation instructions

5000 HARDWARE GUIDE
Revision B
Model 5000
MatDesigner™

2
Wizard™ International, Inc., 4600 116th St. SW, PO Box 66, Mukilteo, WA 98275 888/855-3335 Fax: [phone] wizardint.com
NOTES:

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Series 5000 Hardware Guide
Hardware Guide for the Series 5000
Wizard™ Mat Cutting System
Contents
NOTES:.......................................................................................2
Chapter 1: The Board.................................................................................3
Air Clamp Removal...................................................................................................3
Air Clamp Temporary Fix..........................................................................................4
Air Clamp Replacement............................................................................................4
Air Clamp Test Button ..............................................................................................5
Gantry Alignment......................................................................................................5
Gantry Horizontal Tension .......................................................................................6
Travelling Cable.........................................................................................................7
Chapter 2: The CPU....................................................................................7
Modem Replacement................................................................................................7
Chapter 3: Driver Pak.................................................................................8
Driver Pak Replacement...........................................................................................8
No Power Available to the Driver Pak .....................................................................9
Chapter 4: The Gantry & Trolley Plate....................................................10
Gantry Alignment (See Board)...............................................................................10
Gantry Horizontal Tension (See Board)................................................................10
Gantry Removal.......................................................................................................10
Gantry Replacement...............................................................................................12
Gantry Wheel Adjustment ......................................................................................14
Trolley Vertical Tension..........................................................................................14
Trolley Plate Hinge replacement............................................................................15
Trolley Wheel adjustment.......................................................................................16
Chapter 5: The Head - Changing the Blade............................................16
Restarting the Cut...................................................................................................17

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Wizard™ International, Inc., 4600 116th St. SW, PO Box 66, Mukilteo, WA 98275 888/855-3335 Fax: [phone] wizardint.com
Measure Blade Depth..............................................................................................17
Blade Depth adjustment.........................................................................................18
V-Groove Washer Installation ................................................................................18
Head Removal .........................................................................................................19
Head Installation .....................................................................................................20
Check Head Latch Allen Screw..............................................................................21
Check Plunge Speed...............................................................................................21
Plunge Speed Adjustment......................................................................................21
Chapter 6: Hardware Maintenance..........................................................22
Maintenance Schedule ...........................................................................................22
Daily:.......................................................................................................................................22
Weekly:....................................................................................................................................22
Monthly:..................................................................................................................................23
Ofoad the Air Regulator .......................................................................................23
Use a Surge Protector ............................................................................................24
Reboot Driver Pak when you reboot your CPU....................................................24

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Series 5000 Hardware Guide
5000 Hardware Guide
NOTE: DO NOT USE PLIERS when working on the board or its compo-
nents: ALL PARTS ARE ANODIZED. The exposed part of a scratch will
rub black marks onto the matboard! When screwing in parts with two
consecutive screws, screw first one part way, then begin the second.
It is important that they are screwed in at the same time so that there
is no uneven tensioning.
Chapter 1: The Board
Air Clamp Removal
When anAir Clamp blows, it needs to be replaced. Until the replacement arrives, remove the faultyAir Clamp then cut the blue
airline and insert a screw into airline and replace Clamp. Remaining Air Clamp will hold mat.
Fig A.
Fig A: Air Clamps are located inside Vertical/Horizontal Clamps
Turn off air supply. Move Gantry to the right until it stops. Determine which Clamp has blown and remove the Horizontal or
Vertical Clamp mounting screws with an Allen wrench (Fig B).
Gently lift Vertical/Horizontal Clamp to view small air hose tting. Lift tting from its groove and disconnect it by unscrewing
the two halves (Fig C-D). On later machines, simply pull the two hoses apart.
Fig B. Fig C. Fig D.
Fig B: Remove appropriate Vertical/Horizontal Clamp. Fig C-D: Remove damaged Air Clamp and replace with new Air
Clamp.

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Wizard™ International, Inc., 4600 116th St. SW, PO Box 66, Mukilteo, WA 98275 888/855-3335 Fax: [phone] wizardint.com
Lay Vertical/Horizontal Clamp upside down to look at its construction. Loosen the two Allen screws at each end of the rubber
tube until you can pull the Air Clamp out.
Air Clamp Temporary Fix
Until the replacement arrives, follow these steps to keep working.
Determine if it is the Horizontal Clamp or the Vertical Clamp that has blown. If necessary, run a large mat without the Blade
in the Blade Cartridge (Blade Cartridge must be inserted in Head) and listen for air escaping.
Turn off the air supply. Remove the Horizontal or Vertical Clamp mounting screws with an Allen wrench (Fig B).
Gently lift Vertical/Horizontal Clamp to view small air hose tting. Lift tting from its groove and disconnect it by unscrewing
the two halves. On later machines, simply pull the two hoses apart.
Insert a screw into the airline and replace Clamp. This will keep up the air pressure to the remaining Air Clamp to hold the mat
in place until the replacement arrives.
Replace Clamp and turn on the air supply.
Fig A. Fig B. Fig C.
Fig A: Air Clamps are located inside Vertical/Horizontal Clamps. Fig B: Remove mounting screws. Fig C: Remove the
blown Air Clamp and replace with a screw.
Air Clamp Replacement
Place the metal end of the Air Clamp (side without hose) into slot closest to the end of clamp bar. Push the metal end rmly
into clamp bar and tighten the Allen screw (Fig A).
Fig A:
Fig A: Close-up of Air Clamp within the Vertical/Horizontal Clamp
Grasp the other side of theAir Clamp and stretch until the other metal ring can be inserted into its slot. Push the metal ring into
clamp bar and tighten the Allen screw.

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Series 5000 Hardware Guide
While holding Vertical/Horizontal Clamp near its mounting position, attach air tting and lead the air tting to its pocket. Slip
tting into its pocket as the clamp is being turned over into its mounting position. Align mounting holes and screw Vertical/
Horizontal Clamp back onto The Mat Cutter. Never use sharp instruments to clean out the Clamps or the Rails.
Air Clamp Test Button
Locate the Air Clamp Test Button by gently pulling out the left End Cap on the left literal side of the Board. Do not pull hard
or you may disturb the L-Bracket at the top of the Board. Inside, look for a plastic connector attached with several wires. This
is the Air Clamp Test Button.
Using a pen tip, press in on the small button (Fig A). This will inate the Air Clamps.
This is helpful in determining whether air is reaching the Air Clamps if they are not inating during the cutting sequence.
Fig A.
Fig A: Air Clamp test button is located within the left end cap of the Board.
Gantry Alignment
This is located in the Board Section because the Gantry Alignment adjustment is located on the Board.
L-click on Reset Motors (menu option) to disengage power to the motors. Pull Head and Trolley Plate down until it stops on
bottom rail. Pull Gantry to the left side of the Board until it stops.
Compare right edge of Gantry to right edge of Vertical Clamp (FigA). They should be even; a good alignment can be seen with
the eye or felt with your nger. These Two Surfaces Must Be Flush With Each Other From Top To Bottom. If the Gantry leans
to the left or right of the Vertical Clamp, Gantry needs straightening.
Look at the top and determine if Gantry is leaning to the left or right. Locate Gantry Alignment Screws. The Gantry Align-
ment Screws (two Phillips Screws) are located at the bottom right literal side of the board. The older machines have two knobs
instead of two screws.
If your Board has knobs, NEVER USE A TOOL (PLIERS) TO TURN the
KNOBS!!!

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Wizard™ International, Inc., 4600 116th St. SW, PO Box 66, Mukilteo, WA 98275 888/855-3335 Fax: [phone] wizardint.com
Top of GANTRY leaning to LEFT:
Turn Front Alignment Screw Clockwise (one nearest front of board), and turn Back Alignment Screw Counterclockwise Equal
Distance (Fig B). Always loosen one screw before tightening the other. After each turn adjustment, push gantry full length of
the board several times and recheck Gantry alignment. Repeat as necessary.
Top of GANTRY leaning to RIGHT:
Turn Front Alignment Screw Counterclockwise (one nearest front of board), and Back Alignment Screw Clockwise Equal Dis-
tance (Fig C). Always loosen one screw before tightening the other. After each turn adjustment, push gantry full length of the
board several times and recheck Gantry alignment. Repeat as necessary.
Fig A. Fig B. Fig C.
Fig A: Line up Gantry to Vertical Clamp to determine which way the top of the Gantry is leaning. Fig B: Adjusting for
leaning to the left. Fig C: Adjusting for leaning to the right.
Gantry Horizontal Tension
This is located in Board Section because Gantry Horizontal Tension Adjustment is located on the Board.
The Gantry tension (back and forth) should move with 8-12 lbs. of pressure; a Fish Scale is useful in determining this. If Gantry
Tension is too loose, Gantry will move back and forth (over 3/16”) with Motors Engaged. Please call Wizard before making
adjustments to help prevent possibility breaking the Gantry Cable.
WARNING: If too much tension is applied to the Horizontal Tension Al-
len Screw, the Gantry Cable will break!
L-click on the Reset Motors (Button) to disengage Motors. Slide Gantry to left end of board. Look down the length of upper
rail from the left end; a ashlight may be needed to see long Gantry Cable inside the channel going all the way to the right side
of board.

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Series 5000 Hardware Guide
The Horizontal TensionAllen Screw is located on the upper right corner of the board (Fig A). Horizontal TensionAllen Screw
should be turned Clockwise (tightened) with a 3/16 Allen Wrench until Gantry Cable is almost straight, with just a little sag
in the middle. Pull the Gantry back and forth across full length of the board a couple of times to set the tensioning. Recheck
tension.
Fig A.
Fig A: The Horizontal Tension Screw is located on the upper right side of the Board.
Travelling Cable
Travelling Cable attaches to back of Gantry at the top; other end attaches to back of Board below Board Cable. Make sure that
there is no obstruction to the movement of the Travelling Cable. To check, move the Gantry/Head to the top of the Board then
move to the far right of the Board. If anything impedes movement, the Board will not function properly.
Chapter 2: The CPU
Modem Replacement
Turn off power to computer. Unscrew 4 screws on back of CPU holding cover; remove cover (FigA).
Fig A.
Fig A: Remove cover to CPU
Locate Modem by following phone line into back of CPU (plugged into LINE); unplug phone line.
Follow Modem to inside of CPU and unscrew small screw holding Modem in place. Slide old Modem out and remove it com-
pletely.
Insert new Modem in the same manner. Make sure it is Firmly Seated. Replace screw. Replace the cover and screws.
Plug phone line into Modem port marked LINE.

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Wizard™ International, Inc., 4600 116th St. SW, PO Box 66, Mukilteo, WA 98275 888/855-3335 Fax: [phone] wizardint.com
Make sure phone line is plugged into port marked LINE.
Chapter 3: Driver Pak
Driver Pak Replacement
1. Turn off power to computer. Follow USB Cable from back of the Driver Pak (shoebox-size peripheral that says Wizard) to
where it plugs into the USB Port on the back of the CPU (Fig A).
Fig A.
Fig A: Connection of the Driver Pak to the USB Port
2. Turn off Driver Pak (ip toggle on back to “0”). Unplug USB Cable from USB Port in back of CPU. Large grey Board
Cable is removed by turning black locking ring and pulling gently. Unplug power cord.
3. Replace old Driver Pak with new one.
4. Plug USB Cable (USB-B end) into Driver Pak. Plug USB Cable (USB-A end) into the USB Port in back of CPU (Fig B).
Plug Power Cord into Driver Pak.
Fig B.
Fig B: USB-A plugs into USB Port on CPU. USB-B plugs into Driver Pak.
WARNING: Be very careful when connecting large gray Board Cable.
Align four in-line pins carefully before applying pressure to plug them
in. If forced in incorrectly, they will bend/break, causing malfunction
of the Wizard Mat Cutting system.