Zund M-1600 User manual

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
EN

09
1.45
05-2010
5106015
Original operating instructions
Author Technical Communications
Department, Zünd Systemtech-
nik AG
Composition and publication Zünd Systemtechnik AG
Copyright ©Zünd Systemtechnik AG
Version:
Menu version:
Date:
Doc. no.:

G3 series
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Contents
1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
2Product 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
Tools for the UM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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
Basic device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.8.1.2
Cutter extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8.2 Electrical connection, power consumption . . . . . . . . . . . . . . . . . . . . . . . . 19

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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
3Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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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4Controls 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
Operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.3.1.2
Navigation keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3.1.3
Numerical keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3.1.4
Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3.1.5
Travel keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.1.6
Soft keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3.1.7
Special keys, shortcuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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
OFFLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6.3.2
STOPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6.3.3
ONLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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
Module mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.7.3.2
Inserting/replacing the module (e.g. UM) . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.7.4 Activating a module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.7.5 Tool handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.7.5.1
Marking the tool (e.g.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.7.5.2
Switching the tool manager on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.7.5.3
Tool manager — change tool (UM module) . . . . . . . . . . . . . . . . . . . . . . . 31
4.7.6 Attaching/selecting a tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.7.6.1
Creating a new tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.7.6.2
Selecting a tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.7.6.3
Deleting a tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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4.7.6.4 Saving tool-specific cutter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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
Connection - electrical tools (EOT, DRT, etc.) . . . . . . . . . . . . . . . . . . . . . 35
4.7.8.2
Connection - pneumatic tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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
Automatic feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.9.3.2
Manual feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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
5Description of menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.2 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.3 Description of menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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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7Cleaning 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
Removing the conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.7.13.2
Removing the covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.7.13.3
Fitting a conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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
8Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
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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 develop-
ments
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
E-
mail
[email protected]
www zund.com

Introduction G3 series
Using the documentation
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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".

G3 series Introduction
Using the documentation
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1.2.2 Symbols
Illustration
Text structuring
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.
Close, fix, tighten, in
Open, release, loosen, out
Higher
Lower
Task: Steps to perform
Result: Outcome of the tasks performed.
Prerequisites for performing a task
List of tools

Introduction G3 series
Points to note when reading this operating manual
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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.

G3 series Introduction
Current status of documentation
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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")
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

Introduction G3 series
Standardisation, tests, marking
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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.

G3 series Introduction
Legal notice
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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.
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
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
XL-1600 2XL-1600 3XL-1600

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Publishing details
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G3 series Product description
General
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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.
Fig. 2-1 Directional information
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.
1 Front 3 Left
2 Back 4 Right
Y Y axis X X axis

Product description G3 series
Product identification
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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 see chapter "Introduction", "Standardisation, CE marking"
Structure of the serial number
Example:
1 Manufacturer
2 Product category
3 Device type
4 Serial number
5 Year of manufacture
6 CE marking 1
7 Manufacturer's address
Serial number Description
G3 Product
00L Bar length
25 Table length
0001 Consecutive device number

G3 series Product description
Intended use
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2.2.2 UL marking
Fig. 2-3 UL marking
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".
1 UL marking (Canada, USA)
2 Voltage range
3 Max. current
4 Frequency

Product description G3 series
Cutter - overview
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2.4 Cutter - overview
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)