eastman technology systems maintenance checklist for m9000 static

eastman technology systems maintenance checklist for m9000 static
Congratulations
Congratulations in selecting an Eastman M9000 Static Table. With over 100 years of experience in the cutting
room, Eastman is a world leader in cutting equipment. Every Eastman employees takes pride in each machine
we build and back it with unprecedented support. Our Technical Service department is made up of a dedicated
staff of professionals with years of experience installing, troubleshooting and servicing the M9000 static table.
Each technician is familiar with all aspects of the machine including mechanical, electrical and software.
Eastman Machine Company provides technical phone support and on-site service as required. We offer several
affordable Extended Warranty plans that allows you to continue the superior technical support well after the
machine is past our standard warranty. If you require on-site technical support or would like to schedule additional training, please call our headquarters in Buffalo NY to arrange for a technician.
Technical Support:
Eastman Machine Company
779 Washington Street
Buffalo, NY 14203
United State of America
Phone: 716-856-2200
Fax: 716-856-2068
Limited Warranty. Eastman warrants to the buyer that the equipment shall be free from defects in materials or workmanship
for a period of 180 days commencing on the date of invoice. Any goods or parts claimed by the buyer to be defective must be
returned to Eastman, freight charges prepaid, within the 180 day warranty period. If Eastman determines that the goods or parts
are defective in materials or workmanship, Eastman’s sole obligation under this warranty shall be, at Eastman’s sole option, to repair
or replace the defective goods or parts or to provide the buyer a credit equal to the portion of the purchase price allocable to the
defective goods or parts. This warranty shall not apply if defects are caused by product misuse or neglect, if the machine has
been altered or modified by the buyer, or if other than genuine Eastman belts, emery wheels, knives or parts are used in the machine.
THIS WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THIS PURCHASE. SELLER DISCLAIMS ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE.
Limitation of Liability. Eastman’s liability to the buyer, and the buyer’s remedies from Eastman, whether in contract, negligence,
tort, under any warranty or otherwise, shall be limited to the remedies provided in the foregoing Limited Warranty. In no event shall
Eastman have any responsibility or liability to the buyer for (a) any special, indirect, incidental, or consequential damages, including,
but not limited to, loss of use, revenue, or profit, even if Eastman has been advised of the possibility of such damages, or (b) any
claim against the buyer by any third party. The price stated for the product sold is a consideration for limiting Eastman’s liability.
IMPORTANT
The purchaser must instruct all operators on the proper use of the equipment. All standard industrial safety
measures and equipment should be provided to protect the operator. Operators must be cautioned that improper
or careless use of this equipment may cause personal injury. If you do not have qualified operators to instruct
new persons, contact your Eastman sales representative or Eastman factory direct.
Disconnect electrical power source from before proceeding with any installation, adjustment or repair of the
M9000 Automated Cutting System.
2
Form E-509
Table of Contents
REVISION PAGE ............................................................................................................................................... 4
OVERVIEW ....................................................................................................................................................... 5
Safety Information .............................................................................................................................................. 5
FAMILIARIZATION ............................................................................................................................................ 7
Safety Zone and Stop Devices ............................................................................................................................ 7
USER INTERFACE TERMINAL .......................................................................................................................... 9
UIT Controls: .................................................................................................................................................... 10
OPTIONS Mode ............................................................................................................................................... 13
Software File Relationships .............................................................................................................................. 15
Machine Power UP Procedure .......................................................................................................................... 17
Running A JOB ................................................................................................................................................. 17
Setting up for a Different Materials .................................................................................................................... 17
OPERATION AND SETUP ............................................................................................................................... 17
Changing tools in tool head .............................................................................................................................. 18
M9000 Pressure Calibration ............................................................................................................................. 19
CALIBRATION PROCEDURE .......................................................................................................................... 21
1. Pen X-Y offset-Pen mark (dot) ................................................................................................................... 21
2. Size Calibration ......................................................................................................................................... 22
3. Square Calibration ..................................................................................................................................... 23
4. Mount Theta Calibration ............................................................................................................................. 24
5. Mount XY Calibration ................................................................................................................................. 25
6. Cut Normal Calibration .............................................................................................................................. 26
7. Cut Tool Calibration ................................................................................................................................... 27
8. Punch Calibration ...................................................................................................................................... 28
9. Cut Tool Calibration ................................................................................................................................... 29
MAINTENANCE ............................................................................................................................................... 31
Maintenance Schedule ..................................................................................................................................... 31
Replacing Linear Bearings ................................................................................................................................ 40
Replacing Porex Plastic Table Surface ............................................................................................................. 41
Loading ABS File to the MEI Board .................................................................................................................. 43
TROUBLESHOOTING ..................................................................................................................................... 45
User Interface Terminal Error Messages ........................................................................................................... 45
ELECTRICAL SCHEMATICS & PNUEMATIC DIAGRAM ................................................................................. 53
Pnuematic Diagram 31-9000-19 ....................................................................................................................... 54
31-9000-6 Static Table Schematic .................................................................................................................... 55
31-9000-18 Diagnostic Cabinet ...................................................................................................................... 59
Form E-509
3
REVISION PAGE
4
10/30/03 -
Initial Release of the M9000 manual
9/28/04
Added Pnuematic Diagram 31-9000-19
-
Form E-509
OVERVIEW
Safety Information
WARNING
A warning contains critical information regarding potential safety hazards that can occur during proper
use or misuse of the machine. Failure to follow these procedures may result in serious personal injury
to the user.
CAUTION
A caution contains instructions for the use or maintenance of the machine. Failure to follow these
procedures may result in damage to the machine. Supplementary information may be given in a Note.
Safety And Identification
During the life of the machine, the purchaser agrees to provide to all machine users (including its own
employees and independent contractors) all relevant safety information, including warning labels and
instruction manuals. The purchaser also agrees to maintain the safety features and working condition of
the machine, and to adequately train all users in the safe use and maintenance of the machine. The
purchaser agrees to defend, protect, indemnify, and hold Eastman Machine Company and its subsidiaries harmless from and against all claims, losses, expenses, damages, and liabilities to the extent that
they have been caused by the purchaser’s failure to comply with the terms and instructions of this
manual.
General Safety Precautions
WARNING
This machine is equipped with very sharp and dangerous tools. Keep hands, arms, and hair away from
the cutting area and drive system at all times. Safety gloves, glasses, and appropriate clothing may
prevent serious personal injuries. Disconnect all power sources to the machine when it is not in use or
during routine maintenance, including cleaning and lubrication. The purchaser must instruct all operators
in the proper use of the machine according to the instructions in this manual. This training must include
instruction on the potential safety hazards arising from the use or misuse of the machine. In addition to
such training, the purchaser should provide written work instructions as necessary to ensure correct use
of the machine for specific cutting applications.
WARNING
The purchaser must provide appropriate safety measures and equipment as recommended in this
manual. Observe all statutory requirements concerning the use of hazardous machinery that apply to
your location.
Do not modify this machine or disable safety features. Unauthorized modification may result in serious
personal injuries to the user. A qualified electrician, familiar with applicable codes and regulations, must
make electrical connections to this machine.
Misuse of this machine or use of this machine as part of another machine may result in serious personal injuries to the user.
Safety labels must be kept clean and legible at all times. Call the Eastman Machine factory to order
replacement labels.
Form E-509
5
CAUTION
Eastman Technology Systems equipment is not designed for use in conditions of extreme temperature
or humidity. Operating this equipment in an environment outside the specified ranges may result in
damage and will void the warranty.
Acceptable operating temperature range: 10ºC to 35ºC (50º to 95ºF).
Acceptable operating humidity range:
20% to 80% (non-condensing).
Altitude: We anticipate that the system will operate within all specifications at an altitude up to 1000 m
above mean sea level.
Transportation: During transportation and storage, the system is capable of withstanding ranges from 25oC to 55oC and for periods not exceeding 24 hrs. at up to +60oC.
Lifting/Moving: The lifting or moving of this system must be in accordance with the installation requirements. Failure to adhere to these installation requirements may cause injury to persons or hinderance
or the machine performance.
Hearing protection devices are recommended for prolonged exposure to the noise.
Electrical Component Specifications
Specifications
Computer
Gantry E-box
7-1/2 HP Blower
Gantry
Low Voltage
Power Supply
6
Voltage
120 VAC
120 VAC
230 VAC
440 VAC
120 VAC
5/12 VDC
Current
6 Amp
10 Amp
17.4 Amp
9.0 Amp
1.2 Amp
2/3 Amp
Frequency # of phases
50/60 Hz
Single
50/60 Hz
Single
50/60 Hz
Three
50/60 Hz
Three
50/60 Hz
Single
50/60 Hz
Single
Form E-509
FAMILIARIZATION
Safety Zone and Stop Devices
PAUSE Buttons/Disc
The yellow buttons above the control panel and on the non-operator side of the gantry as well as the
pause discs on each side of the gantry will pause the machine. Activating either the button or the
pause disc will execute a controlled stop of the plotter, with the machine remaining fully powered. After
releasing the pause button or resetting the pause discs and pressing NEXT on the UIT keypad, the
cutter will resume cutting the work in progress. Pressing ABORT will cancel the job.
EMERGENCY STOP Buttons
There are red Emergency Stop buttons located on each side of the gantry as well as on the operator
side right and left ends of the table. Pressing any of the Emergency Stop buttons will execute a
controlled stop of the gantry before cutting all power to the motors and e-box. To release an Emergency
Stop condition, pull out the Stop button hit the ABORT key on the UIT keypad. The table must be rehomed by pressing the ZERO TABLE button before restarting the cutter. Emergency stop mats are also
available as an option.
Form E-509
7
8
Form E-509
USER INTERFACE TERMINAL
The M9000 series Gantry is controlled by the UIT (User Interface Terminal) located on the operator side of
the gantry. After plotting a marker file from the computer the UIT allows the user to operate the machine from
the gantry. With it's push button keypad and four line LED display the operator can easily home the table,
zero a panel or begin cutting a file. The LED display shows the current status of the cutter as well as any
error messages.
Commands are sent to the plotter by pressing specific keys or key sequences on the UIT. Each key on
the UIT has a function and up to two characters (note that not all keys have both a function and characters).
The UIT can be set in one of three modes: Function, Alt Left, and Alt Right. On commands that require data
entry following the pressing of a FUNCTION key the UIT will automatically set itself in either Alt Left or Alt
Right in anticipation of the expected type of input. Alt modes can only be accessed during data entry.
The commands are grouped as follows:
Functions:
This is the default setting for the keypad. Pressing a key in this mode initiates the commands in bold face type at the top of a key. (e.g. <ZERO TABLE>)
Alt Left:
Enables characters shown on the lower left side of a key during data entry.
Alt Right:
Enables characters shown on the lower right side of a key during data entry.
Some commands require only one key to be pressed while other commands require multiple keystrokes
and may sometimes prompt the operator for input.
Form E-509
9
UIT Controls:
1. Gantry Main Power Switch: Turns the power to the gantry on or off.
2. Power Lamp: Indicates if the gantry is on or off.
3. Emergency Stop Button: When the Emergency Stop button is pressed the Gantry will decelerate to a stop
and power will be cut to all axis of motion. The Stop Buttons are 12 VDC normally closed switches and are located on both the operator and non operator
sides of the gantry as well as at each end of the machine. After releasing the
emergency stop the gantry must be "Homed" before proceeding.
4. Emergency Stop Lamp: Indicates if the Emergency Stop circuit is active. If the LED is lit, check each
emergency stop button to make sure they are pulled out.
5. Pause Button: The "Pause Buttons" are generally used to pause a cutting operation to clear material, make
adjustments, inspect work, etc. Pausing the machine stops all axes of motion but does not
cut power to the amplifiers. The servo motors are powered and maintain position. Yellow
pause paddles are located on each side of the Gantry as well as pause buttons on the gantry
and at each end of the machine. To resume cutting simply press the NEXT key on the
gantry keypad and the program will resume where it left off.
6. Pause Lamp: Indicates if the Pause circuit is active. If the LED is lit, check each of the pause buttons and
paddles to make sure they are not active.
7. Tool Enable Lamp: Shows if tool devices are enabled.
8. Tool Enable Switch: Turns the tool head on and off and can be toggled at any time during machine operation. The tool head can be turned off to prevent the tools from coming down during test
runs of a file.
9. Joystick: The Joystick is used to jog the Gantry in the X or Y direction. A fast or slow jog speed can be
selected using the jog button on the keypad. The gantry can only be jogged in either the X or Y
direction at one time and is used to position the Gantry before zeroing the table.
10. EZ Pull Knife Switch: The EZ Pull switch is used in conjunction with the EZ-Pull option for the M9000
table. (Reference the EZ-Pull manual if you have this option.)
11. EC3 Conveyor Switch: The EC3 conveyor switch is used to lock the gantry to the cutting belt when
jogging. This is used during calibration to insure the belt and gantry speeds are
identical.
12. Display: Is a four line 20 Character display used to communicate information between the machine and the
operator. The display may request information from the operator as well as indicating current
status and/or error codes.
13. Command Buttons:
Commands are sent to the plotter by pressing specific keys or key sequences on the UIT. Each key on the UIT
has a function and can have up to two other characters related to that key (Note: not all keys have both a
function and characters). The UIT can be set in one of three modes: Function, Alt Left, and Alt Right. On
commands that require data entry following the pressing of a FUNCTION key the UIT will automatically set itself
in either Alt Left or Alt Right in anticipation of the expected type of input. Alt modes can only be accessed
during data entry.
10
Form E-509
The commands are grouped as follows:
Functions:
Default setting for UIT. Accesses the commands in bold face type at the top of a key.
Alt Left:
Enables characters shown on the lower left side of a key during data entry.
Alt Right:
Enables characters shown on the lower right side of a key during data entry.
Some commands require only one key to be pressed while other commands require multiple keystrokes and
may prompt the operator for additional input.
ABORT: If running a cut file pressing the "ABORT" key causes the carriage to come to an immediate and
controlled stop. Once stopped the UIT will prompt the operator to either press ABORT or NEXT.
Pressing ABORT will exit from the current panel or motion. Pressing NEXT will continue the current
panel or motion.
ALT: Toggles the current mode of the UIT. The ALT key is only active during data entry. Pressing the ALT key
will toggle the UIT between ALT RIGHT and ALT LEFT to allow the user to access all alphanumeric
characters on each of the keys. A left or right arrow in the upper right of the display shows the current
mode.
ALPHA-NUMERIC: A thru Z. Active during data entry. Accessed by pressing ALT, LEFT or RIGHT.
BACKSPACE: Moves the cursor one position to the left when in data entry mode.
CURSOR LEFT: Moves the cursor one space to left and will erase the current character during data entry.
CURSOR DOWN: Not active.
CURSOR RIGHT: Not active.
CURSOR UP: Not active.
CUT DOWN: Drops the primary cutting tool to the cutting surface. This allows the operator to manual cut
straight across the table using the "CUT DOWN" key and the joystick. If the cut direction is
changed the tool will lift rotate and plunge to align the blade with the cut direction.
CUT UP: Lifts the primary cutter from the cutting surface. This key is used in conjunction with the "CUT
DOWN" key when cutting manually.
DOWN: Jogs the gantry carriage in the negative Y-axis direction. (Towards the operator) The gantry carriage
will move as long as the key is pressed or until the carriage encounters a limit switch. See "JOG" for
speed change.
ENTER: Sends information from the UIT to the computer. It is only active during data entry mode.
INS: Not active
JOG: Toggles the carriage jog speed from fast to slow when using the joystick or jog keys. The high speed is
the manual MOVE VELOCITY while the slow speed is the SLOW VELOCITY value in MACHINE.INI
setting. When the program is first enabled the default slow manual move speed is set to MOVE VELOCITY from the MACHINE.INI file
LEFT: Jogs gantry to the negative X-axis direction. (To the operators left side) The gantry will move as long as
the key is pressed or until the carriage encounters a soft limit. See "JOG" for speed change.
LOAD: Allows user to load a new CMD file from the UIT panel. After pressing LOAD the UIT will display the
current file and prompt user for a new file name. Using the ALT mode the operator may then enter the
new file name (.CMD extension need not be included) using a valid file in the current directory. When
done typing the file name the user must press ENTER to accept the new file.
Form E-509
11
NEXT: After zeroing the table the "NEXT" button is pressed to begin cutting, draw and or marking the current
file plotted to the cutter. The first time "NEXT" is pressed the UIT displays the marker length while the
second time the "NEXT" key is pressed the gantry begins cutting.
OFFSET: Moves the gantry carriage from it's current position to the offset position of the primary cutter. This
effectively moves the primary cutter into position over the reference point (usually the pen device or
laser pointer).
OPTION: Allows option mode commands to be entered in the UIT. Values are set by pressing a two letter key
and then inputting a new value for a specific setting. The available commands are listed in the
OPTIONS section in this manual.
PANEL HOME: Moves the gantry carriage to the current PANEL HOME position set either by the most recent
PANEL ZERO or in the current cut file.
PEN: Toggles the pen tool up or down. The default is pen up.
RESCAN: Causes the cut file program to reset to the top of the current panel.
RIGHT: Jogs the gantry in the positive X-axis direction. (To the operators right side). The gantry will move as
long as the key is pressed or until the carriage encounters a soft limit. See "JOG" for speed change.
ROTATE 90: Rotates the Z-axis Tool Spindle 90 degrees counter clockwise from it's current position.
ROTATE CCW: Rotates the Z-axis tool spindles counter clockwise. The tools will rotate as long as the key is
held down. The rotation speed can be changed between fast and slow by toggling the "JOG"
button.
ROTATE CW: Rotates the Z-axis tool spindles clockwise. The tools will rotate as long as the key is held
down. The rotation speed can be changed between fast and slow by toggling the "JOG" button.
SCAN: Allows user to scan to a specific panel within the current cut file. Press scan and the UIT will prompt
for a panel number. The UIT automatically go into ALT LEFT mode and allow user to select a panel
number. Press ENTER to accept the panel number.
TABLE HOME: Moves the gantry carriage to the TABLE HOME position. The table home position is defined by
the location the gantry, Y-car and tool spindles stop when using the "ZERO TABLE" function.
The "TABLE HOME" key allows the operator to return to the zero position without the time
required to zero the table.
UP: Jogs the gantry carriage in the positive Y-axis direction (away from the operator). The gantry carriage will
move as long as the key is pressed or until the carriage encounters a limit switch. See "JOG" for speed
change.
ZERO PANEL: Sets the current gantry and Y-car position as the home position. The cutter will use this
position as it's zero reference point when cutting a file. The "ZERO PANEL" key should be used
to position the cutting or marking tools on the material before pressing "NEXT" to begin cutting.
The laser pointer is used to position the tool head on the material. The selected tool will begin
cutting/marking at the referenced laser position.
ZERO TABLE: This function homes the gantry by moving each axis one at a time until they hit their respective
home switches. This will square the Gantry as well as return each axes to it's known starting
point. The Home Position can be offset from the home switches as determined in the Easicut
software.
WARNING The "ZERO TABLE" key must be pressed each time the system is Powered
Up, Easicut is started or an E-STOP is activated. Failure to Zero Table can
result in the Gantry and/or Y-car traveling past table limits and crashing into
end stops.
12
Form E-509
OPTIONS Mode
Options mode is used to change plotter operation variables through the user interface terminal. Changes
made using the options commands are not saved and are lost as the plotter program is exited. Should you
wish to make a permanent change, (for example, offset calibrations) you must write them down and then
enter them into the "Machine Setting" in Easicut.
To enter the options mode press the OPTION key on the UIT. The display will then prompt for a two-letter
option. After typing the two letter command press the ENTER key and you will be prompted for a value or
the action will take place immediately. If prompted, input the new value and press the ENTER key again.
Note that if you do not enter a new value and press the ENTER key, the current value is maintained. Option
codes values can also be entered on the computer keyboard in the plotter status window. The two letter
option codes are not case sensitive.
(AA) Change Acceleration: Sets the acceleration rate of the carriage.
(AB) Airbrush On/Off: Activate and deactivates airbrush option. (If available.)
(BB) Layer Names On/Off: Toggles the layers names command on or off. With layer names turned off this
allows CMD file formats that reference CUTN and CUTF commands to be compatible with the new motion control software.
(CC) Change Laser Max Power:
(DD) Digitizing Mode On/Off:
For laser plotters only, it sets the maximum power for the laser. Expressed as a number between 0.0 and 1.0. This will adjust the cutting kerf
for specific cut speeds. It should never be set above 0.95. This command
is only available on machines that have a laser cutting tool. (Not Pointer)
Enters or exits the pattern digitizing mode. (See the section on Digitizing in
the EasiCut manual.)
(EE) Change Overall Rate:
(FF) Laser Service Modes On/Off: For laser cutting machines only. Sets the software mode to enable several
power and alignment tests. (Not for laser pointers)
(GG) Load Cut File: This command loads the current CMD file active in the Easicut window to the plotter file
for cutting. This is the same as plotting the file through the Easicut software from the
computer terminal.
(HH) Change Slow Speed: Sets the slow JOG speed of the gantry, Y-car and Z-axis. This command can
be used to slow down the gantry when trying to jog the laser pointer to a fixed
point on the table.
(HOME) Panel Home: This does the same function as the ZERO TABLE key on the UIT. By typing this
command into the Plotter Status window on the computer, you can zero the table
without walking over to the gantry.
(II) Change Time Interval:
(KK) Key Dump On/Off:
Sets the update interval for the motion control card. There is no reason ever to
adjust this value except during calibration of the M9000 system at the factory.
Changing this variable will result in inaccuracies in cutting.
Enables or disables the key dump feature. Key dump is normally off. With it turned
on the signature of the key pressed is displayed on the computer's screen. This is
a valuable diagnostic tool that helps troubleshoot UIT keypad problems.
(LL) Change Cut Speed: Sets the top speed during manual use of the primary tool. Changing this variable
does not effect the cutting speed when cutting in automatic mode.
(NN) Next: After plotting a file, this command starts the machine cutting or penning the active panel. Like
pressing NEXT on the UIT this can be typed into the Plotter Status window at the computer.
Form E-509
13
(OO) Options: Allows the operator to enter the "Options Mode" of the UIT from the computer terminal. This
command is only available from the computer keyboard and duplicates the OPTIONS key on
the UIT.
(PP) Pause On/Off:
Toggles on or off any <PAUSE> command within the current CMD file. With pauses
turned off the plotter will move from panel to panel without prompting for the NEXT
command. This feature works in conjunction with CMD files that have pre-designated
pauses in the file for product inspection. (This is not related to the pause buttons on the
gantry.)
(QQ) Exit Plotter W: Exits the Easicut program. When reopening Easicut the table must be homed by
pressing the ZERO TABLE button on the UIT keypad. Failure to home the system will
result in the gantry running into the end stops and/or causing damage to the system.
(RR) Set CMD repetitions:
Sets the number of times to repeat the current CMD file. Note that the next
repetition of the CMD file will start from the plotter position at the end of the last
repetitions of the CMD file. When repetitions are used zero marks are disabled.
(SS) Change Scale Factor: Sets the scale factor of the current CMD file. This allows user to expand or
contract the size of the entities within a CMD file by an input coefficient. For
example entering a value of 0.5 will yield parts 50% of normal, therefore entering
a 2.0 will yield parts twice the normal size.
(TT) Change Laser Minimum Speed: Available on M90 Laser cutting machines only. Sets the minimum
speed at which the laser tube will fire. This is useful for reducing
cutting kerf as the gantry decelerates to a stop. If set to high, parts
may not be cut all the way to side intersections.
(UU) Tools On/Off: Toggles the primary tool on or off. Works like Tool On/Off switch.
(VV) Speed Change:
Sets the top speed during dry haul when the machine is neither marking nor cutting. It
is the speed that the machine moves between cuts.)
(WW) Pen Speed Change: Sets the top speed during manual use of the pen device. Pressing the Option
button followed by WW will change the speed that the pen will mark in manual
mode. The pen must be down and the gantry jogged before it takes effect.
(YY) Reference Mark On/Off:
Toggles all zero marks in a CMD file either on or off. Note that it affects both
the <MARK> command and <VMARK> command present in many CMD files.
(ZP) Zero panel: Sets the current gantry and Y-car position as the home position. The cutter will use this
position as it's zero reference point when cutting a file. (See ZERO PANEL button.)
(ZZ) Set Display Units:
Toggles the UIT and computer display between different units of measurements like
inches (IN), feet (FT), centimeters (CM). The current units setting is indicated in the
upper right corner of the display.
(11) X Offset Change: Sets the X offset of the primary tool from the reference laser pointer. Setting the Offset
from the UIT or Plotter Status screen is only temporary while the system is powered.
The cutter will default to the original settings after software is exited or system is
powered down. All offset setting need to be made on the calibration screen or in the
Option/Machine menu to be permanently saved.
(22) Y Offset Change: Sets the Y offset of the primary tool from the reference laser pointer. Setting the Offset
from the UIT or Plotter Status screen is only temporary while the system is powered.
The cutter will default to the original settings after software is exited or system is
powered down. All offset setting need to be made on the calibration screen or in the
Option/Machine menu to be permanently saved.
14
Form E-509
(33) Z Offset Change:
Sets the rotational offset of the primary tool from the sensing point. Setting the Offset
from the UIT or Plotter Status screen is only temporary while the system is powered.
The cutter will default to the original settings after software is exited or system is
powered down. All offset setting need to be made on the calibration screen or in the
Option/Machine menu to be permanently saved.
(44) Cut Up Time Change: Set the time delay from when the tool up command is set and the gantry begins to
move. This prevents the gantry from moving and catching material while the tool is
going up.
(55) Cut Down Time Change: Set the time delay from when the tool down command is set and the gantry
begins to move. This prevents the gantry from moving and catching material
while the tool is going down.
Software File Relationships
Easicut is Eastman’s Windows XP based plotter software (Other versions of Windows available). When opened,
Easicut can read in several data file types to initialize the plotter’s settings. These data files are ASCII text files
with specific formats, which must be correct to be read. Some files can be edited through the Easicut software,
while others may be accessed using Microsoft Notepad. All are located in the Eastman directory in the Easicut
or Plotter folders. The following is a short description and a chart of the various files:
PLOTTER.KEY: Required on all machines using a UIT and on some older M90 models. This file maps the
keypad data coming from the UIT to the plotter program.
DESIGN.CMD: The file containing a pattern’s coordinates and commands read by PLOTTERW. The CMD file
uses Eastman’s proprietary file format. Easicut automatically converts several file formats to
CMD files when operator selects and opens them in the software.
MACHINE.INI: Contains values pertaining to calibration, velocity profiling, table dimensions, and layer to tool
mapping. Easicut writes to this file as changes are made in the Machine Setting window.
MACHINE.INI is read by Easicut, modified as necessary (for example, to accommodate a
change in tool offsets) and sent to PLOTTERW. It is important to always keep a copy of your
latest MACHINE.INI so that you can always reload your machine setting if something becomes
corrupt.
PLOTTER.SRV: Optional. Used only on plotters with laser cutting device. Contains default values for laser test
firing and troubleshooting.
PLOTTER.DRL: Required only when <DRILL> function is called by CMD file. Contains default values used by
<DRILL> function when specified in CMD file.
MATERIAL.INI: Contains tool control information relating to different material types. The JOB file temporarily
overwrites the machine settings set in the MACHINE.INI file and takes precedence over the
JOB.INI file.
JOB.INI:
Form E-509
Contains tool control information relating to different material types and or cut files. The JOB
file temporarily overwrites the machine settings set in the MACHINE.INI but does not take
precedence over the MATERIAL.INI files.
15
Motion Control Software Functions
PLOTTERW
Motion Control Software called by
Easicut and runs the machine. This
program takes the DESIGN.CMD file
and creates the motion profile based
on the JOB, MATERIAL and
MACHINE.ini file parameters
MATERIAL.INI File
These files contain the tool
settings for various materials.
The settings over ride the
MACHINE.INI and the JOB.INI
EASICUT.JOB
files FILE
JOB.INI FileFILE
EASICUT.JOB
These files contain the tool
settings for various jobs. The
settings over ride the
MACHINE.INI file but are
superseded by a
MATERIAL.INI file.
DESIGN.CMD File
This is the cut file or marker file
that is opened in Easicut and
sent to PLOTTERW to be cut.
Easicut 2000
This is a Windows based interface
software used to enter parameters
and load files. The information from
the UIT, MACHINE.INI, MATERIAL
and/or JOB files are combined and
loaded into the PLOTTERW
MACHINE.INI File
This file contains the machine
settings, calibrations, table
parameters, etc. and is written
to by the EASICUT software
16
UIT
Easicut Dash Board
User Interface Panel is located
on the gantry and is used to
enter information into
EASICUT and run simple
command sets.
User Interface in the Easicut
software that allows you to
map tools, change cut speeds
and pressures on the fly.
These changes are only
temporary and are not saved to
the Machine.ini
Form E-509
OPERATION AND SETUP
Machine Power UP Procedure
1. Turn on the Computer CPU and wait until computer is fully booted.
2. Turn on the Gantry using the gantry On/Off switch above the UIT panel.
3. Power the E-Box(es) on.
4. Start the EasiCut software by double-clicking on the Windows Desktop.
**To power down the system, reverse the power up sequence starting with closing EasiCut
WARNING Power Up machine using the Machine Power Up Procedure to avoid unpredictable machine movement. Failure to follow this procedure may cause serious
personal injury and/or damage to machine.
Running A JOB
1. Spread material on the table, making sure it is straight and parallel with X-axis.
2. Press the TABLE ZERO button on UIT. This will bring the gantry to it's calibrated home position. (Only
required when first powering up the machine or after hitting an E-Stop)
3. Position laser pointer to the edge of the material where you want to begin cutting.
4. Send the cut file to the gantry by pressing the "Cut" icon in Easicut.
5. Send the cut file to the gantry by pressing the "Cut" icon in Easicut.Press the ZERO PANEL button on UIT.
6. Close off large open sections of the table using Blast Gates (if installed on the M9000) or by covering open
areas with a nonporous material. This will increase the vacuum and reduce the load and current draw on the
blower motor(s). Leaving large sections of table uncovered can cause material to slip and/or damage blower
motor(s).
7. Turn on the table vacuum switch.
8. Press "NEXT" on UIT. This will calculate the pattern length and width compared to the table length and width.
If the pattern is larger than the cutting surface an error message will appear on the UIT. Pressing NEXT a
second time will start job cutting.
9. To run same pattern, repeat steps 7 & 8.
Setting up for a Different Materials
1. Remove all material from previous job.
2. Open cut file for new job
3. Change tools according to job requirements.
4. Adjust over cut setting in Easicut according to material thickness. *
a) Go to | Options | Job | Layers |
b) Select tool from pull down menu
Form E-509
17
c) Change Over cut value in the Over cut window.
* NOTE: The tool settings and cut pressures can be saved in a job file and loaded into the cutter for each
material being cut. (See Easicut Manual or Help Screen for JOB files)
Changing tools in tool head
1. Turn the power off to the gantry making sure it is unable to move.
2. Remove desired tools from tool mounts by:
a) Loosening the (2) allen head screws on the tool holder.
b)
Carefully slide tool holder off tool mount.
3. Attach desired tools to empty tool mounts. If a different tool type is installed, re-map the new tool type to the
tool holder. Reverse tool removal process.
CAUTION Failing to re-map a tool after changing tool types can result in damage to
the table top, tool and or tool spindle. (Example: Changing a Punch to a
Drag Knife)
4. Open the job file in Easicut that corresponds to the current job and material.
5. Tools DO NOT need to be recalibrated unless cut accuracy is critical to .010 or less. If calibration is needed
go to Tool Calibration section of this manual.
18
Form E-509
M9000 Pressure Calibration
Note: Pressure calibration is set by an Eastman Service Technician at machine installation.
Calibration settings should be changed by the customer ONLY if prior settings are found to be
inaccurate.
Knob
1. Set main pressure regulator to
125 psi by turning regulator
knob.
Main Pressure
Regulator
Back Cover
Cable
2. Remove back cover and leave cable
connected to PC board. Place on a
support that will lift back cover to
relieve strain on cable.
Support
3. Remove tool head air tube
from pneumatic transducer
output port. Install calibration
gauge at transducer output.
Calibration
Gauge
#27-26024
Pneumatic
Transducer
Form E-509
19
Pressure Slide
Switch
4. Set Easicut cut pressure at 10 psi
and adjust at regulator using zero
screw adjustment.
Pressure meter should read 10 psi
at gauge.
5. Set Easicut cut pressure at 100 psi..
6. Push "cut up" and "cut down"
on control panel UIT.
7.
Adjust "span" screw until calibration gauge reads 100 psi.
Calibration Gauge
#27-26024
Zero Screw
Span Screw
Repeat steps 5 through 10 at least 3 times. Be sure to push tool up/down on
control panel between each test calibration.
8. Compare Easicut cut pressures to calibration gauge pressures at 10, 20, 40,
60, and 100 psi.
9. Remove calibration gauge, attach tool head air tube to pneumatic transducer
output port. Remove shunt wire connector and replace with rear cover
connector. Attach back cover assembly.
20
Form E-509
CALIBRATION PROCEDURE
The following calibration procedures are used to calibrate each machine tool to one another to insure accurate cuts
between tools. The calibration are initially done at machine installation and should not need to be done unless a
tool mount is changed. The calibration numbers are stored in the machine.ini file in the Easicut 2000 directory. A
backup copy should be stored in that directory as well on a disk.
The M9000 tool calibration should be performed in the following order:
1.
2.
3.
4.
5.
6.
7.
8.
Pen X-Y offset.
Table sizing.
Automatic gantry squaring.
Tool mount X-Y for all tools.
Theta axis offset.
Tool Calibration (circles and squares).
Test Cut Using Design.cmd.
Test Cut Using Design.cmd and production material.
Before beginning the calibration procedure:
- Remove all cutting and punch tools from all tool mounts.
- Check that the pen tool is rigidly attached to the pen mount
- Open the Easicut 2000 software and "zero" the table by
depressing the TABLE ZERO button on the operator UIT.
Tools required :
- 2.5" to 3.5" wide masking tape.
- High quality tape measure that has inch and centimeters.
- 60" to 72" Roll of paper for test cutting.
- Sample production material for test cutting.
- Tools that will be used in production cutting.
- #2 Pencil.
1. Pen X-Y offset-Pen mark (dot)
This calibration procedure establishes the offset between the pen and the laser pointer. The laser pointer is
considered the zero point for the machine.
a)
b)
c)
d)
Put a small length of masking tape under the pen mount.
Press "PEN" several times on the UIT to make a mark on the masking tape.
Press "ZERO PANEL" on the UIT.
Using the UIT joystick, move the gantry and tool head to position the laser pointer over the pen mark on
the masking tape. For precise positioning of the gantry movement use “Option” HH on the UIT to set a
very slow jog speed of about 0.1 cm/sec. (0.04 in/sec)
e) Read the "X" and "Y" values on the UIT display and write them down.
f) Click on Options/Calibration/Mount X-Y/Pen 1 in the Easicut 2 menu and enter the negative of the
values for X-Y in their respective Offset windows.
Example: (If X=+0.27 on UIT then enter -0.27).
g) Verify the Pen Mount X-Y offset by pressing "PANEL HOME" on the UIT. Press "PEN" and the mark
should be exactly over the previous pen mark. If not repeat steps (a) through (e) again until you have
calibrated the pen offsets correctly.
h) Click “APPLY” then “OK” to save the changes. Press “CANCEL” to keep original settings.
Form E-509
21
2. Size Calibration
The size calibration ensures that the machine will cut parts to the correct size specified by the CMD file. This
calibration is important to make sure that the cut pieces are cut to the correct dimensions. The calibration
must be performed when the cutting machine is first installed, when a new tool head or new tool mount is
installed, or following any disassembly of cutting machine drive components.
Size Calibration Procedure:
a) Open the Easicut 2000 software.
b) On the menu bar click on Option/Calibration and select the “Size” tab on the calibration screen.
c) Press the “Set X and Y Scale” button to load the Calibration test.
d) Layout a sheet of paper about 1.2 x 1.2 meters onto the cutting surface and apply vacuum.
e) Line the laser pointer to the lower left corner of the piece of paper and press the ZERO PANEL
button on the UIT.
f) Press the NEXT button on the UIT and let the machine run through the calibration. The machine
will pen a 1-meter by 1-meter square onto the sheet of paper.
g) Using a measuring tape, measure the length of the penned lines in both the X and Y direction,
these should measure 100.00 cm (39.370 inches). If the lines do not measure this value, enter the
measured value into the software in the correct box and click on the “Apply” button.
h) Continue with steps (d) through (g) until both the X and Y measurements are correct.
i) Press APPLY then OK to save the new values to the machine.ini file.
22
Form E-509
3. Square Calibration
The square calibration is done to ensure the gantry will run square to the table to prevent damage to the linear
bearings and gantry side plates, this also ensures that the cut parts will be cut proportionally. The calibration
must be performed when the cutting machine is first installed, when a new tool head or new tool mount is
installed, or following any disassembly of cutting machine drive components.
Square Calibration Procedure:
a) Open the Easicut 2000 software.
b) On the menu bar click on Option/Calibration and select the “Square” tab on the calibration screen.
c) Select the “Automatic Gantry Square” button in the software to load the calibration test.
d) Layout a sheet of paper about 1.2 x 1.2 meters onto the cutting surface and apply vacuum.
e) Line the laser pointer to the lower left corner of the piece of paper and press the ZERO PANEL
button on the UIT.
f) Press the NEXT button on the UIT and let the machine run through the calibration. The machine
should be penning a 1-meter by 1-meter square with diagonals connecting all four corners, onto the
sheet of paper.
g) Using a measuring tape, take a measurement of each of the diagonals D1 and D2 (D1 is from the
lower left corner to the upper right corner, D2 is the lower right corner to the upper left corner.)
These measurements should be 141.42 cm (55.677 inches), if the diagonals do not measure this
value enter the measured value into the corresponding box in the software and click on “APPLY”.
h) Repeats steps (c) through (f) until both diagonals measure correctly.
i) Press APPLY then OK to save the new values to the machine.ini file.
Form E-509
23
4. Mount Theta Calibration
The Mount Theta calibration is done to check the squareness of each tool compared to the X motion of the
gantry. This also ensures that all cuts line up when cutting from opposite directions. The calibration must be
performed for each tool mount and should be done when the cutting machine is first installed, when a new tool
head or new tool mount is installed, or following any disassembly of cutting machine drive components.
Mount Theta Calibration Procedure:
a) Open the Easicut 2000 software.
b) On the menu bar click on Option/Calibration and select the “Mount Theta” tab on the calibration
screen.
c) Select the Mount that you wish to calibrate from the tool mount menu.
d) Click the “Run Theta Calibration” button to load the calibration test.
e) Lay out a 2 inch by 15-inch piece of masking tape in the X-axis and zero the panel in the lower lefthand corner of the tape.
f) Press NEXT button on the UIT and run the calibration test.
g) Lift the cut masking tape and observe the final cut, the final cut should be along the same line as
the initial cut. If there is a deviation between the initial and final cuts adjust the Theta offset
according to the instructions in the software.
h) Reselect the mount and run the Theta calibration again to check the deviation in the two lines.
i) Continue to run this calibration for all of the mounts.
j) When finished with each mount Press APPLY then OK to save the new values to the machine.ini
file.
24
Form E-509
5. Mount XY Calibration
The Mount XY calibration offsets the centerline of the each spindle to the laser pointer ensuring that all tools are
working from the same point of origin. This allows the operator to switch between cutting tools during a cut and
have all the cut lines line up regardless of which tool is used. The calibration must be performed for each tool
mount and should be done when the cutting machine is first installed, when a new tool head or new tool mount
is installed, or following any disassembly of cutting machine drive components.
Mount XY Calibration Procedure:
a) Open the Easicut 2000 software.
b) On the menu bar click on Option/Calibration and select the “Mount XY” tab on the calibration screen.
c) Select the Mount that you wish to calibrate from the tool mount menu.
d) Click the “Run XY Calibration” button to load the calibration test.
e) Using 2” by 10” strips of masking tape create an “L” shape with the two pieces of tape intersecting in
the corner of the “L”.
f) Line up the laser pointer in the lower left hand corner of the “L” shape and press the ZERO PANEL
button and NEXT button on the UIT to run the calibration test.
g) Observe the cut on the “L” shape masking tape surface, the cut line should split the pen line in half in
both the X and Y direction.
h) Make adjustments according to the guidelines in the software to adjust the cut line until the pen line
is split.
i) Once the X and Y offsets are determined for the first mount move on to the next mount by selecting
Mount 2 from the tool mount menu. Continue until all mounts are calibrated.
j) When finished with each mount Press APPLY then OK to save the new values to the machine.ini file.
Form E-509
25
6. Cut Normal Calibration
The Cut Normal calibration is done to ensure that the machine knows the offset between the two sides of each
cutting blade. This is important for shapes such as circles where the start and end point must connect to
produce a cleanly cut part. The calibration must be performed for each tool mount and should be done when the
cutting machine is first installed, when a new tool head or new tool mount is installed, or following any disassembly of cutting machine drive components.
Cut Normal Calibration Procedure:
a) Open the Easicut 2000 software.
b) On the menu bar click on Option/Calibration and select the “Cut (Normal)” tab on the calibration
screen.
c) Select the Tool that you wish to calibrate from the tool menu.
d) Click the “Run Normal Calibration” button to load the calibration test.
e) Layout a 2” by 10” piece of masking tape along the length of the table.
f) Line up the laser pointer in the lower left hand corner of the masking tape and press the ZERO
PANEL button and NEXT button on the UIT to run the calibration test.
g) This test will cut two straight lines in the masking tape, the two lines should share a common
midpoint.
h) If there is any deviation in the alignment of this midpoint intersection, one half the measured
difference will need to be entered into the software in the Normal Offset box.
i) Once the two lines connect to make one straight long line and the difference between the two cut
lines is zero, select the next tool from the tool menu and run the calibration again.
j) When finished with each tool Press APPLY then OK to save the new values to the machine.ini file.
26
Form E-509
7. Cut Tool Calibration
The Cut Tool calibration is performed to determine the leading and trailing cutting edges of the cutting blade.
This test also calibrates a tangent offset for each tool to guarantee that shapes such as circles will connect
through the start and end points. The calibration must be performed for each tool mount and should be done
when the cutting machine is first installed, when a new tool head or new tool mount is installed, or following any
disassembly of cutting machine drive components.
Cut Tool Calibration Procedure:
a) Open the Easicut 2000 software.
b) On the menu bar click on Option/Calibration and select the “Cut Tool” tab on the calibration screen.
c) Select the Tool that you wish to calibrate from the tool menu.
d) Click the “Run Tool Calibration” button to load the calibration test.
e) Lay out a sheet of paper about 1 meter by 1 meter and apply vacuum. Position the laser pointer in
the lower left-hand corner of the piece of paper and press the ZERO PANEL button on the UIT.
f) Press the NEXT button on the UIT to run the calibration test.
g) The calibration test will draw, and then cut two 10-cm circles and two 10-cm squares using the pen
and the selected cutting tool. Measure both squares and circles to confirm size.
h) The circles and squares should be able to be easily removed from the piece of paper. The internal
corners of the cut out squares should be clean without any excess over cut and the circles should
be easily removed without any hangers at the start/finish point of the circle.
i) Any over cut in the corners should be removed by adjusting the Blade Lead and Trail settings
according to the software instructions.
j) The Tangent Offset setting should be adjusted to compensate for any material fragments left at the
start/finish area of the 10-cm circle.
k) Once the circles and squares can be cleanly removed from the piece of paper without excess over
cut or material fragments, select the next tool from the tool menu and repeat steps (e) - (k).
l) When finished with each tool Press APPLY then OK to save the new values.
Form E-509
27
8. Punch Calibration
This calibration test is done to offset the punch tool to the proper location. This is done by penning a 10-cm
square with two lines connecting the midpoints of each line. The punch will then fall at the intersections of all of
these lines. The difference between the projected punch area and the actual punch area will be factored into the
X and Y punch offset.
Note:
Not all applications require a punch. If your machine is not equipped with a punch you can skip
this calibration procedure.
Punch Calibration Procedure:
a) Open the Easicut 2000 software.
b) On the menu bar click on Option/Calibration and select the “Punch” tab on the calibration screen.
c) Select “Punch” from tool menu.
d) Click the “Run Punch Calibration” button to load the calibration test.
e) Lay out a sheet of paper large enough to run several 10-cm squares. Position the laser pointer in
the lower left hand corner of the sheet of paper, and press the ZERO PANEL button on the UIT.
f) Press the NEXT button on the UIT to run the calibration test.
g) Adjust the X and Y offsets to compensate for any differences between the projected punch point
and the actual punch point.
h) Reselect the punch tool from the tool menu and run the punch calibration again to check the X and
Y calibration.
i) When finished with the Punch calibration, Press APPLY then OK to save the new values to the
machine.ini file.
28
Form E-509
9. Cut Tool Calibration
The V-Notch calibration allows the operator to set the depth of the V-Notching tool in the software and make
adjustments to the orientation of the V-Notch. The V-Notch tool is used to cut a predetermined size V-Notch
into a pattern.
Note:
Not all applications require a V-Notch. If your machine is not equipped with a V-Notch you can
skip this calibration procedure.
V-Notch Calibration Procedure:
a) Open the Easicut 2000 software.
b) On the menu bar click on Option/Calibration and select the “Notch” tab on the calibration screen.
c) Select “VNCH” from tool menu.
d) Click the “Run Notch Calibration” button to load the calibration test.
e) Lay out a sheet of paper large enough to run several 10-cm squares. Position the laser pointer in the
lower left hand corner of the sheet of paper, and press the ZERO PANEL button on the UIT.
f) Press the NEXT button on the UIT to run the calibration test.
g) Adjust the normal and tangent offsets to compensate for any differences in the notch orientation and/
or adjust the tool depth until you achieve the desired results.
h) Reselect the notch tool from the tool menu and run the V-Notch punch calibration again to check the
X and Y calibration.
i) When finished with the V-Notch calibration, Press APPLY then OK to save the new values to the
machine.ini file.
Form E-509
29
Calibration Trouble Shooting
Tools will not come
down when the
calibration test is run:
Verify:
Pen does not come
down during calibration:
1. From the menu bar click on Options/Job and choose the "Layers" tab, select the
PENME layer from the layer menu. Make sure that the pen tool is setup for the
PENME layer.
1. The tools are on the correct spindles in the tool menu.
2. Tools are mapped correctly in the Easicut software. (Refer to the software manual
or Help screens for Tool Mapping).
2. Verify that the pen tool is mounted to the pen mount in the tool menu.
30
During the "Cut Tool
Calibration" one set
of circles and
squares are larger:
1. Check the cutting tool for proper setup, check to see if the blades are mounted on
the correct side of the knife holder. Correct and rerun the calibration test.
While running the
"Mount Theta Calibration", the tool has
an offset that cannot
be corrected in the
software:
1. Check the tightness of the tool to the spindle mount.
2. Check for any slack in the Z axis belt, re-tension the Z axis belt if necessary and
rerun the calibration test.
3. Check the knife bolt for any excess play between the depth limiter and the knife
holder.
Changes don’t take
effect on the position
of the gantry when
running the "Square
Calibration":
1. Zero the table and retry the calibration.
UIT indicates, “Machine Done” without
running the calibration test:
1. Verify the tool called out in the tool pull down in the calibration window is also on
the tool mount menu in the lower center of the Easicut screen. The machine will
not run a tool specific calibration without the tool being placed on a mount in the
software.
Software not saving
settings during
calibration:
1. Make Sure that after each calibration procedure click on "APPLY" then "OK" to
save settings.
2. Run the calibration again and click on the "APPLY" and then "OK" button to
accept calibration settings.
Form E-509
MAINTENANCE
Maintenance Schedule
Caution
It is important to perform regular maintenance on the equipment . A daily,
weekly and monthly schedule should be maintained. Failure to do so can
result in more frequent breakdowns, damage to the equipment and/or injury.
Proper maintenance will help ensure the reliable operation of your M9000 digital cutting system. You should
allow 5 to 10 minutes for daily inspection, 30 minutes for weekly inspection, an one hour for monthly inspection.
Time invested on these tasks will minimize downtime due to machine problems. Eastman machine company is
not liable for damage as a result of poor maintenance and any resulting damage would be repaired at the user's
expense. All maintenance should be performed by qualified personnel, following all safety procedures. The
following is a recommended Maintenance Schedule:
Daily (Start of each shift)
1. Carefully inspect the machine and cutting table area. Look for any debris, loose cables or other obstructions that may interfere with the machine movement and cutting.
2. After switching on the computer and plotter carriage, start the plotter program. Check the X and Y-axis for
motor torque and backlash. If backlash is excessive on either axis, adjust as required.
3. Check the pen lift. Pen should move smoothly up and down. Ensure pen is seated properly in mount, and
that retaining strap is tight.
4.
Warning:
Activate machine pause before performing this prcedure . Failure to do so can
result in damage to the equipment and/or serious personal injury.
Check tool head. Check that tools are securely fastened to tool shaft. If the round knife blade is installed
check that the blade mount rotates freely. Check the blade mounts for excessive side to side play. Check
blade edge for nicks and replace as necessary. Check limiting disks relative to material thickness and
requirements. If a drag knife is installed check cutting depth relative to material thickness and requirements.
Adjust drag knife foot as necessary.
5. At the end of each work session make sure to turn both the computer and plotter carriage off. Remove any
CD's or floppy disks from disk drives and clean up scrap materials from the cutting table.
Weekly or every 40 hours:
Warning: Before performing any of the weekly tasks make sure the gantry and computer are
turned off at the disconnect and locked out. Failure to do so can result in damage to the equipment and/or serious personal injury.
1. Turn off gantry and computer at the disconnect and lock out power to the machine per your lock out/tag out
procedures.
2. Lubricate table rail linear bearings with Eastman lubricant 67-26324.
3. Lubricate air reciprocating cylinder couplings using Eastman lubricant 67-26009.
4. Lubricate reciprocating tool head shafts using Eastman lubricant 67-26009.
Form E-509
31
5. Using compressed air, clean dust and debris from inside the carriage.
6. Use a clean cloth to wipe down the Y-axis rails and lubricate.
7. Tighten any loose fasteners on the carriage to specified torque values.
8. Remove the cover from the Y-car. Inspect the cutting head assembly.
9. Rotate the tool holders by hand. They should rotate freely without any play relative to each holder and the
drive motor. If not, belt replacement or adjustment is required.
Monthly (or every 200 hours):
Warning: Before performing any of the monthly tasks make sure the gantry and computer are
turned off at the disconnect and locked out. Failure to do so can result in damage to the equipment and/or serious personal injury.
1. Turn off gantry and computer at the disconnect and lock out power to the machine per your lock out/tag out
procedures.
2. Remove X-axis drive block covers.
3. Use compressed air to remove any dust and debris from the drive block.
4. Lubricate air cylinder couplings using Eastman lubricant 67-26009.
5. Lubricate tool head shafts using Eastman lubricant 67-26009.
6. Check drive belts for signs of wear such as cuts, frays, or missing teeth. Replace if required.
7. Check belt tension. Belts should be tight enough to eliminate excessive backlash between the driving and
driven pulley. Overly tight belts will wear faster and place excessive loads on bearings. Adjust at motor
mount by loosening screws and pulling timing belt pulley and tightening motor mount screws to specified
torque.
8. Check all shafts and pulleys. The pulleys should be seated tightly on the shafts. Check pulleys set screws
and tighten as needed to specified torque.
9. Move plotter manually by pushing on the Y-carriage. X-axis drives require two people. Carriage and drives
should move with continuous smooth force. Listen and feel for "hard" spots that will indicate a failed linear
bearing.
10. Check the Y-axis backlash (gear play). The Y-axis gear should be snug against the y-axis rack. To adjusted backlash, loosen the (8) rail y-car backlash plate screws. Push the small y-car gear toward the y-car
rack. Be careful not to bind the y-car gear with the y-car rack. When proper adjustment is reached tighten
the backlash plate screws to specified torque. After adjusting the backlash the Y belt tension may need to
be adjusted.
11. Check the X-axis backlash (gear play). The X-axis drive gear should be snug against the X-axis rack. To
adjust backlash, loosen the (8) rail x-car connector screws enough to allow X-carriage to move. Turn the (2)
backlash adjuster screws until there is no backlash (play) between carriage and table. Be careful not to
bind the x-axis carriage with the x-axis rail. When proper adjustment is reached, tighten the (8) rail car
connector screws to specified torque. Note that it is important to keep the carriage level. It is a good idea
to place a bubble level on the carriage to ensure the carriage remains level as the carriage is raised and
lowered. Perform this adjustment to both front and back x-cars. After adjusting the backlash the X belt
tension may need to be adjusted.
12. Inspect carriage wheels for any material threads or debris wound up around the wheel shafts. Checks
wheels for debris and remove as needed.
13. Check all electrical plug connections to ensure they are securely fastened.
14. Inspect the x-festoon wire or e-chain (if so equipped) for wear and movement.
32
Form E-509
15. Replace drive block covers and secularly torque fasteners.
16. Check for unusual noises coming from blower assembly. If clicking or grinding noises heard then call
Eastman service technician.
2000
1000
200
50
8
Form E-509
Lubrication Chart
2
5
1
4
h
3
4
1
*5
6
*6
Maintenance
Frequency
33
Yearly or every 2000 hours:
Below is a recommended maintenance checklist for the M9000 static table. It' provides a good guideline for
yearly maintenance and can be copied and kept as a maintenance log.
The page numbers on the Check list references the M9000 Illustrated Parts List manual E-509.
Example:
Control Panel Assembly (Page 13) - Refers to Page 13 of the M9000 Illustrated Parts List.
EASTMAN TECHNOLOGY SYSTEMS
MAINTENANCE CHECKLIST FOR M9000 STATIC TABLE
Festoon & Cable Assembly: pg 8
Comments
Signoff
Comments
Signoff
Check & Secure festoon mounting track
Check & Secure festoon roller track
Check festoon end stop
Check festoon track splice
Check festoon trolley with webbing strap
Check X-Axis cable festoon assembly
(Loose connections or wear in cables)
a) Main AC power cable
b) X1/X2 power cable
c) Y/Z po
d) UIT cable
e) Hall effect cable
f) Encoder cable
g) I/O cable
h) Air hose
Front Cover Assembly: pg 11
Check & secure stop disks with rod
Check limit switch & switch bracket
Check slide bearings & bearing mounts
34
Form E-509
Back Cover Assembly: pg 12
Comments
Signoff
Comments
Signoff
Comments
Signoff
Check & Secure stop disks with rod
Check limit switch & switch bracket
Check slide bearings & bearing mounts
Check Emergency Stop switch & wiring
Check Pause switch & wiring
Control Panel Assembly: pg 13
Check U.I.T. control assembly & cables
Check Emergency Stop switch & wiring
Check Pause switch & wiring
Check Main Power switch & wiring
Check joystick & cable/wiring
Check tools on/off switch & wiring
Check & Secure all screws
Front End Plate Assembly: pg 14
Inspect drive belt (cracks, thread
separartion)
Check & oil large pulley bearings
Check X1 home switch & wiring
Check wiring for 5 & 12VDC power supply
(Verify 5 and 12 VDC power)
Check & Secure all set screws
a) Large Pulley
b) X1 Motor drive pulley
c) Spur gear
Remove & inspect THK linear bearings(2)
Form E-509
35
Front End Plate Assembly: Cont'd
Comments
Signoff
Comments
Signoff
Check & adjust backlash for X1
Check & Secure all screws
Back End Plate Assembly: pg 16
Inspect drive belt (cracks, thread separation)
Check & oil large pulley bearings
Check X2 home switch & wiring
Check X Limit switch & wiring
Check & Secure all set screws
a) Large Pulley
b) X1 Motor drive pulley
c) Spur gear
Remove & inspect THK linear bearings(2)
Check Electrical Regulator for calibrated
output pressure
Inspect & clean X-axis card
a) Check all MTE connections
b) Check DB-15 Encoder connectors
Inspect all cables wired into electrical pan
a) X1/X2 power cable
b) Y/Z power cable
c) Main AC power cable
d) U.I.T. cable
Check pull bracket, cable mount & E-chain
mount
Check & adjust backlash for X2 motor
assembly
Check & Secure all screws
36
Form E-509
Main Tube Assembly: pg 18
Comments
Signoff
Comments
Signoff
Check Y-Home switch
Check Y-Limit 1 & 2 switch
Check Y E-chain cables
a) Multi-tool & Y I/O cable
b) Y power & encoder cable
c) Z power & encoder cable
d) Airline tubing
Check & Secure linear Thompson Rail
a) Oil or grease
Check & Secure white gear rack
Check & Secure all screws
Y-Carriage Assembly: pg 20
Inspect drive belt (cracks, thread separation)
Inspect & clean Y-axis I/O card
a) Check all MTE connections (wiring)
- Multitool, Sol 1,2,3, Pen, Laser, Boost
- Y I/O cable
Check Y Motor disconnect plug
Examine Solenoid Block
a) Use manual trigger to fire each solenoid
b) Check for air leaks
Check & Secure all set screws
a) Large Pulley
b) Y Motor drive pulley
c) Spur gear
Inspect Thompson Linear bearings
Adjust Y-motor assembly backlash
Check & Secure all screws
Form E-509
37
Tool Head Assembly: pg 22
Comments
Signoff
Comments
Signoff
Comments
Signoff
Inspect drive belt (cracks, thread separation)
Grease 16mm bearings(3) for air cylinders
- Use Loctite High performance grease
Check Z Motor disconnect plug
Inspect & oil Pen lift bearing assembly
Test Z-Home proximity sensor
a) Check MTE connection on Y axis I/O
Secure Z Motor drive pulley set screws
Examine cylinder motion
- Fire cylinders
manually via solenoid block
Rack & Rail Assembly: pg 24
Clean & oil THK rails
Check Rack & Rail gap(s)
Check Rack & Rail for wear
Secure all screws
a) Tighten 1/4-20 2" Rack plate screws
b) Tighten #10-32 1/2" Rack button screws
c) Tighten M3x16 Rail screws
d) Tighten 1/4-20 3/8" Dust cover screws
e) Tighten #8-32 3/8" Cam(limit) screws
f) Tighten 1/4-20 3" Shock mount screws
Static Table Assembly: pg 26
Secure 3/8-16 1" Frame screws
Secure angle brace(s)
Examine Porex and/or Lexan surface
Check table square and level
38
Form E-509
Vacuum Components: pg 28
Comments
Signoff
Comments
Signoff
Comments
Signoff
Examine PVC vacuum plumbing
a) Check Silicon seals
b) Vacuum leaks
Examine 7.5HP blowers
E-box Assembly: pg 30
Clean fan filter
Use dry air to clean inside
Tighten all screw terminals
Secure all plugs and connections
Check Vdc at X1,X2,Y & Z amp 162-185Vdc
Software: Easicut v. 2.2.17 PlotterW
Calibrate M9000 & Tools
Save Machine.ini, Job & material files
Save Machine & Job defaults
Upgrade Software
Additional Comments
Inspectors Signature
Form E-509
Date
39
Replacing Linear Bearings
The below is a step by step procedure on how to replace the THK linear bearings on the M9000 Static Table or
EC3 Conveyor cutting system. Replacement of the linear bearings will not only restore the performance of your
machine, but it will also prevent other problems such as increased spur gear wear, decreased cutting performance, and increased THK rail wear.
Note:
All work should be performed by a qualified technician with power turned off to the machine in accordance with companies lockout procedures.
Removing Linear Bearings:
1.
Power the machine down using the proper shut down/lockout procedure.
2.
Remove the fiberglass cover from both the operator and non-operator side of the gantry. Use caution when
removing the covers, the wires connecting the pause and emergency stop switches can be damaged if not
disconnected.
3.
Remove the shock absorbing mounts from one end of the machine.
4.
Place 2 x 4 blocks under the each end of the gantry for support when the bearings are removed.
5.
Remove the four 10-32 screws holding the linear bearing block to the side plate. Repeat this step until all
four linear bearings unbolted.
6.
Unscrew the backlash adjusting screw from the backlash-adjusting block and slide the bearings out.
7.
Remove the four M4 x 12-mm screws holding the bearing to the aluminum backlash-adjusting block.
8.
The bearings can now be slid off the rail toward the end where the shock absorber mount was removed.
Installing the New Bearings:
1.
Remove bearings from the package, and press the Zerk fitting provided, into the bearing. Using a grease
gun and the grease gun adapter that was included with the machine, fill the bearings with white or clear
lithium grease.
2.
Slide the bearings onto the THK rail, reinstall the aluminum backlash adjusting block back onto the
bearing using the M4 x 12mm screws.
3.
Position the bearing and bearing block directly under the backlash-adjusting block and replace the 10-32
screws into the bearing block finger tight.
4.
Begin screwing the backlash adjusting screws into the backlash-adjusting block. Use a 6-inch level
across the top of the side plate to ensure that both backlash-adjusting screws are being adjusted evenly.
5.
Adjust the backlash adjusting screws until the spur gear contacts the gear rack. The backlash adjusting
screws should be adjusted until the backlash between the gear and the gear rack can no longer be felt.
Making the spur gear too tight can cause increased wear on the entire gantry drive train, so it is critical
that this tolerance be set perfectly.
6.
Tighten the 10-32 screws holding the bearing block to the side plate and recheck the gear backlash.
Readjust if necessary.
40
Form E-509
Replacing Porex Plastic Table Surface
This procedure outlines the proper operation for changing the Porex table surface on the M9000 Static cutting
system. Adhering to the following steps will reduce costly down time and ensure that the machine will operate
properly when the procedure is complete. A clean and true cutting surface will guarantee that the machine can
perform to its optimum level and that the cut parts will come out clean and precise.
Note:
Always consult a trained Eastman Technician for the required size and the number of Porex table
surfaces that are needed for your individual application.
Removing the Porex Surface:
1.
Remove the aluminum table end covers from both ends of the machine. If the machine is equipped with a
Blue Jay End cutter it must also be removed.
2.
Starting from one end of the machine begin scraping the Porex surface from the wooden tabletop using a
flat wide putty knife. Be careful not to damage the wood surface underneath.
3.
Remove all pieces of the Porex material until only the wooden tabletop remains.
4.
Scrape the remaining glue from the wooden tabletops. A solvent may be required in areas where glue is
built-up and difficult to remove.
5.
Mask off the table rack and rail using plastic drop cloths and masking tape. This is important to keep
glue over spray off of the precision ground rails. The cutting gantry should also be covered using additional plastic drop cloths.
Replacing the Porex:
1.
Carefully remove the Porex sheets from the shipping container, use caution in material handling as the
sheets can easily be cracked and broken through careless handling.
2.
Stack the Porex sheets onto the table at the end where gluing will start.
3.
Test fit the first piece onto the table by lining the sheet up with the table edge. Using a pencil mark the
edge of the sheet on the table.
4.
Flip the sheet upside down with rough side up and place it on the far side of the mark you just made.
5.
Using 3M Super 77 Spray Glue apply a medium coat of glue on the table surface, holding the can about
12”-14” away. Spray the glue in an even pattern back and forth the width of the sheet marked on the table.
This coat should be even, not too wet and have a frosted appearance. Repeat the process by going back
and forth across the table surface in a slow sweeping motion to ensure the entire table surface is coated.
(This coat should also have a frosted appearance.) An entire can of spray adhesive is required to ensure
enough glue is on the table surface.
WARNING
Form E-509
When applying the spray adhesive it should be done in a well ventilated
area. Anyone working in the area is required to wear a respiratory to
prevent inhalation of glue. Follow all safety instruction and cautions on
spray can.
41
Caution If the area the machine is located has a high humidity (above 40%) use a
fan over the prepared table surface to prevent moisture from setting on and
reacting with the 3M adhesive applied to table and Porex surfaces. Allow
enough room between sheets for Porex to expand and contract based on
the high and low seasonal temperatures of the factory.
6.
Using about half a can of glue per sheet, spray a light dusting of glue onto the rough side of the Porex
sheet. This will provide a tacky surface for the glue already applied to the table to adhere too.
7.
With the assistance of another person carefully line up the Porex sheet with the end of the tabletop.
Leave equal distance between the rack plate and the Porex sheet on either side of the machine. Once
the sheet is lined up it can be set in place. Using a tile roller, roll the entire surface of the Porex sheet
making sure that the sheet is completely bonded to the table surface.
8.
Utilizing another drop cloth, cover the surface that was just laid down and prepare the next sheet of Porex
for application. Leave about an 1/8” between the first and second sheet of Porex. Mark the edge of the
second sheet.
9.
Remove the sheet and prepare the surface for gluing.
10.
Follow the procedure outlined above for all additional Porex sheets.
11.
Any Porex overhanging at the end of the table can be trimmed off using a sharp knife.
12.
Any additional accessories that were removed from the machine (Blue Jay End Cutter) can now be
reinstalled.
Seam Gluing Procedure:
1.
Once all the panels are glued in place, the drop cloths and masking tape can be removed from the
machine.
2.
Using a hot glue gun (67-26035) and Eastman Special Porous Plastic Glue Sticks (67-26034), fill in the
seams left between panels. Make sure that the glue penetrates the entire seam from the table surface to
the top of the Porex sheet. Fill in all of the seams between sheets but leave the gaps between both the
rack plates and the Porex sheet empty.
3.
Using a sharp putty knife or straight knife, scrape the excess glue from the top of the seam.
4.
Continue this procedure until all seams are filled and scraped.
42
Form E-509
Loading ABS File to the MEI Board
The MEI board is a 4 axes Servo control board located in the cutter computer. The ABS file contains all the
default settings for the MEI program that interfaces with both the Easicut and Plotterw software. The ABS file
contains factory default tuning for each axis of motion on the automated cutter. Changes to the default settings
on the MEI board or if the ABS file becomes corrupt will affect machine operation and can cause errors during
normal operation. The factory defaults are loaded in the Eastman Directory located on your Easicut computer,
they can also be found on the original software CD supplied with the machine. When installing a new MEI board
or if the ABS file becomes corrupt you can load the ABS file from disk using the MEI program supplied on the
cutting computer.
1.
Power-up the M9000 using the proper start-up sequence:
2.
a. Turn on the computer and let it fully boot up.
b. Turn on E-box(s) .
c. Turn on cutting gantry.
d. Start Easicut software.
Close Easicut software and open MEI software (MC_DSP_95).
3.
With the MEI software open go to the View menu on the top tool bar. Click on the Hardware Summary
option.
Form E-509
43
4.
This will open a window that will show a controller list.
5.
Select the "Download From File" option located in the lower left corner of the hardware summary window.
AMC_CONV.ABS
- For Medium Speed Conveyor MEI Board without Belt Encoder
EC3M9000.ABS
- For Conveyor Gantry MEI Board
M9000.ABS
- For M90 Gantry (Old Style Gantry) MEI Board
M9000_96.ABS
- For M9000 Gantry MEI Board
MED.ABS
- Not Used
MEDI.ABS
- Not Used
MEDSP.ABS
- Not Used
PC-DSP.ABS
-Standard MEI setting from factory
WARNING
Loading the wrong ABS file can result in damage to the motors or cause
the gantry and/or Y-car to runaway. Care should be taken when restarting
Easicut after reloading the ABS file. Be ready to press an E-STOP in case
of problems.
6.
If you have an M9000 cutter, select the M9000_96.abs file from the C:\Program Files\Eastman\Easicut
2000\Options directory. If you have something other than an M9000 machine, select the correct ABS file
from the list. Otherwise consult factory.
7.
Click on the "OPEN" button.
8.
Click "YES" to replace the existing ABS file.
9.
Close the MEI Setup program and reopen Easicut.
44
Form E-509
TROUBLESHOOTING
User Interface Terminal Error Messages
Any troubleshooting or maintenance performed on the machine should be done by a qualified technician.
Before performing any work follow proper electric lockout procedure for your facility, All power to the machine
should be off and proper care taken to prevent damage to the machine and/or injury.
WARNING Failure to remove power to the machine and take proper safety precautions
when performing maintenance and/or troubleshooting can result in injury or
death. Any work should be performed by a qualified technician!
UIT Error Messages
Abort X1 Axis Fault
Abort X2 Axis Fault
Abort Y Axis Fault
Abort Z Axis Fault
The "Abort Axis Fault" error codes indicate a fault with one of the gantry servo
axes located in the gray E-box. There are a variety of problem which can cause
this error. By perform the following test, it will help identify the source of the error.
1. Verify there is power to the servo amplifiers by removing the E-box cover and
locating the set of (4) Servo Amplifiers.
a) A GREEN LED on the servo amplifier indicates the amplifiers are powered
and ready. Press the ENTER key on the UIT, "Zero the Table" and continue with cutting. If the problem persists contact an Eastman Machine
technician.
b) A RED LED on the amplifiers indicates the amplifier has power but is
faulted.
* Check the voltage going from the High Voltage Power supply to the
amplifiers. The voltage should be approximately 165 VDC. If the voltage is
less than 140 VDC, check your incoming AC voltage.
* If the incoming AC Voltage to the E-box is correct, but the DC voltage to
the amplifier is less than 140 VDC, unhook the DC power to each amplifier
one at a time. Measure the DC voltage from at the High Voltage power
supply to see if it measures 165 VDC.
* If your able to isolate one amplifier pulling down the High Voltage Power
supply swap the bad amplifier with it's counterpart. (X1 and X2 amplifiers
can be swapped and Y and Z amplifiers can be swapped) Determine if the
problem stays with the amplifier or with the motor/cables) Swap the 16 pin
connector and the A, B and C motor power leads between amplifiers.
Make sure that you wire the A, B and C wires in the correct order.
* If the problem follows the amplifier the amplifier is bad. If the problem
stays with the motor/cables, the motor/cables are bad.
* If you unhook all the amplifiers from the High Voltage Power supply and the
DC voltage does not return to 165 VDC then the power supply is bad.
Form E-509
45
Abort X1 Axis Fault
c) If none of the amplifiers are lit, verify 165 VDC input power to the amplifiers.
Abort X2 Axis Fault
* If there is no DC input voltage present then check the (2) 15 Amp fuse located
Abort Y Axis Fault
Abort Z Axis Fault
in E-box and incoming AC voltage to E-box.
* If the fuses are good and there is 115 VAC coming into the High Voltage
Power Supply then the power supply is bad.
* If there is AC Voltage coming into the E-box but not to the High Voltage
Power Supply, verify all E-Stops are off and the (2) 15 Amp fuses are good.
d) If one amplifier is not lit swap the amplifier with another to verify it is the
amplifier and not the cabling or motor. (X1 and X2 amplifiers can be swapped
and Y and Z amplifiers can be swapped) Swap the 16 pin connector and the
A, B and CW motor power leads between amplifiers. Make sure that you
wire the A, B and C wires in the correct order.
* If the problem follows the amplifier the amplifier is bad. If the problem stays
with the motor/cables, the motor/cables are bad.
2. Remove the gantry cover from the non-operator and verify the 5-12 VDC power
supply is working properly.
a) Measure the voltage between the BLACK and RED leads to verify it is
between 4.8 - 5.2 VDC. If the voltage is outside this range, adjust the
potentiometer until it falls within acceptable levels.
b) Measure the voltage between the BLACK and White leads to verify it is
between 11.8 - 12.2 VDC. If the voltage is outside this range, adjust the
potentiometer until it falls within acceptable levels.
c) If there is no 5 or 12 VDC power present, then replace the power supply.
3. If the problem is intermittent or happens at the same spot on the table, check
motor cables for broken wires. Power the system up and with the gantry sitting
still, move and twist all the cables to see if you can create a fault.
4. Check the MEI board by reloading the ABS file.
5. Verify amplifier tuning by making sure the current limit and gain potentiometers
are set properly. Consult factory for proper settings.
6. If the AXIS FAULT error occurs at power up and can not be cleared, check each
of the limit switches to verify they are not active.
a) Push each limit switch in and out verifying that they are functioning properly.
b) Remove the Non-operator side cover to verify that the X and Y limit switch
LED's are lit on the X-axis board.
c) Verify all E-Stops are not active (See "Emergency Stop" Trouble Shooting).
46
Form E-509
Abort X1 Error Limit
Abort X2 Error Limit
Abort Y Error Limit
Abort Z Error Limit
The "ERROR LIMIT" indicates the following error between the command position and
the actual position for that axes was greater than the limit set on the MEI board. This
typically indicate that the acceleration or velocity is set higher then the machine can
perform. It may also indicate a problem with one of the servo drive or a mechanical
problem in the axis.
1. Verify accelerations and velocity in Easicut and the JOB file. If the problem
occurs at the same spot each time a particular file is run then decrease the
acceleration.
2. Power down the system and push the gantry across the full length of the table to
verify that both side move freely. Move the Y-Car by hand verifying it moves
smoothly across the entire width of the table.
a) If one or both sides of the gantry or Y-Car do not move smoothly check:
* Linear bearing making sure they are not damaged or clogged with material.
* Remove the gantry end covers and check all pulleys and belts for wear or
signs of slipping.
3. Shut down the Easicut software and start the MEI program on the PC. With the
Gantry turned off, reset the encoder counts and push the Gantry and/or Y-Car by
hand to verify the encoders are counting properly. You will need to click on each
smiley face to pull up the individual axis. (Axis 0 - X1, Axis 1 - X2, Axis 2 - Y and
Axis 3 - Z):
a) If the "Actual" and "Error" positions for each axes are not equal but opposite
signs (+/-) then reload the ABS file to the MEI board.
b) If problem persists check, motor cables for continuity and verify solder joints
and crimps at each motor connector. Check Hall and Encoder wires with a
volt meter to verify 0 and 5 VDC when slowly spinning the motor.
c) Verify encoder is not damaged by swapping motor cables at the X-Axis board
and rerunning test with power turned off to the gantry. Make sure the cables
are switched back before powering up system. (Swap X1 and X2 or Y and Z)
4. In the MEI program, if the actual and commanded encoder counts are off by more
than 100 counts and the cables are good then the MEI board may be bad.
Emergency Stop
The "EMERGENCY STOP" indicates that one or more of the red Emergency Stop
buttons are active. The switches are normally closed and activated when the button
is pressed or from an open circuit. This may be the result of a pressed button, bad
switch, broken wire, or bad 12 VDC power supply.
1. Check all E-Stop buttons on both sides of the Gantry and any remote buttons.
Push each E-STOP button in and out to verify they are off.
2. Check to see if the red E-Stop light on the operator and Non-operator side of the
Gantry is lit. If one of the red lights are lit check E-STOP Button and wiring on
that side of gantry. This will verify the gantry E-Stop buttons are working.
3. Remove operator side cover of gantry. Verify the low voltage power supply is
properly adjusted. (5 VDC between Red and Black wires, 12 VDC between
White and Black wires) If voltage is too high or low adjust the potentiometer on
the power supply board. Reinstall the gantry cover making sure to reconnect ESTOP circuit.
Form E-509
47
Emergency Stop
Continued
4. Remove Non-operator side cover on Gantry while keeping the E-STOP circuit
connected and check the X-Axis board. There should be (2) Green LED’s lit on
the front center of the board. If only one green LED is lit, check the button and
wiring on Non-operator side of gantry. If neither green LED’s are lit check the
button and wiring on operator side of the gantry. This will verify the E-STOP
signal is getting to the X axis board.
5. Unplug the “Table Remote” cable from the back of the Computer. Jumper pins 4
and 8. If the E-Stop condition can be cleared by pressing “Enter” on the UIT then
the table remote E-Stop boxes are bad. Check wiring and E-STOP buttons on
all remote E-STOPs.
6. Unplug the conveyor E-box to computer cable and jumper pins 10 and 12. This
will bypass the whole E-Stop circuit. If the E-Stop condition can be cleared by
pressing “Enter” on the gantry then this will point to a bad cable or button in the
E-STOP circuit. With an ohm meter, check the continuity of the wires and
switches back through the circuit. (See Wiring Schematic 31-9000-6 page 2 of
4)
Pause Active
When a Pause Button or Paddle is active the gantry will decelerate and stop. The
operator will be unable to jog the gantry or execute any commands from the UIT
other than "NEXT" or "ABORT". This may be a result of a button or paddle being
active, wiring or a bad/ loose switch.
1. Check all PAUSE buttons and PADDLES on both sides of gantry and remote
"PAUSE BUTTONS to verify they are not activate. Push each button and
paddles in and out to verify they are off.
2. Check to see if the green Pause light on the operator and Non-operator side of
the Gantry is lit. If one of the lights are lit check the switch and/or wiring on that
side of gantry. This will verify the gantry Pause buttons are functioning.
3. Press "NEXT" on the UIT to continue with the active cut program loaded in the
plotter program. Press "ABORT" to stop cutting and plot another cut file from
the PC.
Axis not Square
The "AXIS NOT SQUARE" error message indicates the gantry is twisted. When
"Zeroing the Table", if the second X-axis limit switch does not activate within a fixed
distance of the first X-axis limit switch the table is considered out of square.
1. Verify that both CAM plates for the end of travel limits are located the same
distance from the end plate to insure gantry is squared.
2. Verify both X-axis limit switches activate when touching CAM plates.
3. If gantry is damaged and is no longer square it may taking pushing the "ZERO
TABLE" button twice to square the gantry.
48
Form E-509
No Frames
The MEI (Motion Control Board) is waiting for move information from the PlotterW
program. This is an indication that the Computer CPU may not be fast enough to
process the information or may be tied up with another task.
1. Reduce the Marker File size.
2. Turn off the machine and reboot the computer.
3. Add RAM to the computer.
X1 Axis Not Enabled
X1 Axis Not Enabled
Y Axis Not Enabled
Z Axis Not Enabled
The "AXIS NOT ENABLED" error indicates the amplifier for the corresponding axis did
not receive the input from the block relay in the E-box to enable.
1. Open up E-box to determine if any of the amplifiers are enabled by observing a
Green LED on each Servo Amplifier. If none of the amplifiers are enabled then:
a) Verify the Enable relay block located in Gantry E-box is functioning.
b) Verify Enable signal from I/O board in computer. Remove Computer cover and
locate amplifier enable LED on I/O board.
2. If only one amplifier is not enabled check wiring between the Enable relay block
located in Gantry E-box and the amplifier. (Pins 2 & 9 on the amplifier) .
X Home Not Found
Y Home Not Found
Z Home Not Found
The "HOME NOT FOUND" fault indicates the home sensor in the given axis was not
activated during the ZERO TABLE sequence. This could be caused by several
problems including a stuck limit switch or bad home sensor.
1. Remove the Non-operator side Gantry cover and locate LED's on the X-axis board.
While pushing the home switch, verify the corresponding LED turns on and off. If
LED does not turn on:
a) Check switch to determine if it is operating correctly.
b) Verify wiring by swapping connector on X-axis board with another switch. IF
LED comes on then wiring is good.
2.
Form E-509
*
If LED does not come on then wiring or switch is bad.
*
If LED does not come on then switch or X-axis board is bad.
If while homing the Gantry is moving slow in the X direction away from the Home
Switch check the X-Axis Limit Switches. This is an indication that the limit is
active.
49
The M9000 may also develope mechanical or electrical problems that may not be displayed on the user
interface. Below is additional troubleshooting for problems that may occur without providing an error message.
Additional Troubleshooting
UIT not Lit
1. Remove operator side gantry cover and verify on the low voltage power supply that
there is 5 VDC between both red leads and either black lead.
a) If no voltage verify AC power to board or replace power board.
b) If voltage is above 5.2 or below 4.8 VDC then adjust the potentiometer through
the hole in the plexiglass cover.
c) If voltage is between 4.8 and 5.2 VDC.:
* Verify there is 5 VDC at the UIT.
* If 5 VDC present at UIT then UIT is damaged and needs to be replaced.
Any Button Pressed
on UIT displays same
message.
1. One of the buttons on the UIT is stuck down. UIT must be replaced. To verify that
button is stuck, type a few commands directly into the "Plotter Status" window in
Easicut and verify that machine responds.
1. Verify that the tools are on the correct spindles in the tool menu.
Tools do not come
down when operating in 2 Verify tools are mapped correctly in the Easicut software. (Refer to the software
manual mode.
manual or Help screens for Tool Mapping)
Gantry Runs to end of 1. Verify layer name appears underneath the picture of the cut tool at the bottom of
the Easicut window. If the layer name does not appear under a tool then the layer
File and Displays JOB
is not mapped.
COMPLETE without
cutting the file.
2. In Easicut 2 and later versions you can drag and drop the Layer Name to the cut
tool in the bottom of the Easicut window.
The UIT Displays a
Blinking Cursor
1. System may have been powered up in wrong order. Turn on Gantry, close Easicut
and reopen Easicut.
2. The UIT to Computer RS-232 line may have bad connection.
a) Close Easicut and start windows "Hyper-terminal by clicking on the Windows
Start Button/All Programs/Accessories/Communication/Hyper-terminal.
b) Name the new connection Comport 2 and click OK.
c) In the Connect To" window select the "Connect Using" as COM2.
d) In the Port Setting Window:
* Set "Bits per Second" to 2400.
* Set "Data Bits" to 8.
* Set "Parity" to None.
50
Form E-509
The UIT Displays a
Blinking Cursor
* Set "Stop Bits" to 1.
* Set "Flow Control" to None then click OK.
3. Type on the computer keyboard and see if the characters appear on the UIT
screen. Also push different buttons on the keypad and see if you get different
symbols on the Hyper-terminal screen.
4. If you do not get characters on the UIT or on the Hyper-terminal, verify the connection between UIT and computer.
a) Disconnect UIT from the Comport in back of computer .
b) Jumper pins 2-3 on the computer comport by touching them together with a
paper clip or metal screw driver.
c) Type on computer keyboard and make sure what ever is typed shows up on
computer screen. If no characters show up on Hyper-terminal then comport 2
is bad or not properly configured.
5. If you do get characters on the Hyper-terminal screen, then reconnect the comport
to the computer and unplug the UIT connector from the bottom pan of the nonoperator side gantry and repeat steps (a) through (c) above. If you do not get
characters back then the UIT to Computer cable has a bad connection.
6. If you do get characters on the Hyper-terminal screen, reconnect the comport to
the gantry and unplug the RS-232 connector from the bottom of the UIT and repeat
steps (a) through (c) above. If you do not get characters back then the UIT to
Non-operator side gantry cable has a bad connection. If the characters appear on
Hyper-terminal then the UIT is bad.
Form E-509
51
Slivers in Y Direction
1. Check backlash in the Y axis by physically trying to move the Y-car with gantry
powered. If their is backlash power down the gantry and remove tool cover.
a) Inspect all pulleys for signs of slippage on the shaft.
b) Tighten the Y-axes motor belt by loosening motor mounting screws and sliding
motor until the belt is tight.
c) With the power to the gantry off move the Y-car along the Delron rack. Make
sure that the spur gear makes good contact with the rack from one side of the
gantry to the other. If the spur gear does not make full contact loosen the
screws holding down the Y-axis rack. Position the Y-car on one side of the
table. As the Y-car passes each screw make sure that the rack makes full
contact with the spur gear before tightening down the screw. Push the Y-car
across the entire width of the table until all screws are tightened.
2. Inspect all pulleys on the Y-car for any indication it is slipping on the shaft. Mark
the pulley and shaft with a marker and cut a file. When the machine stops, check
the mark to verify pulley did not slip.
As the table cuts the Y- 1. Inspect all pulleys on the Y-car for any indication it is slipping on the shaft. Mark
axes Home position
the pulley and shaft with a marker and cut a file. When the machine stops, check
begins to move to one
the mark to verify pulley did not slip.
side
2. Verify there is no RF interference which may be causing the encoder signal to be
off.
3. The Y-axes motor may have a bad encoder and needs to be replaced.
4. MEI board may be going bad and picking up or loosing encoder counts.
No Display on UIT
1. Check 5-12 VDC Power Supply P/N 31-12660-1 on operator side of gantry. Verify
that there is 5 VDC on pins 2 and 4 on power supply and J1 pins 1 and 4 on UIT.
If voltage is not between 4.7 VDC and 5.3 VDC adjust the potentiometer on the
power supply. If voltage is 0 replace power supply.
2. Check continuity of wires going from power supply to UIT board.
3. If 5 VDC present at UIT connector replace UIT unit.
Buttons on UIT do no
Work. Display is lit.
1. Verify continuity of pins 2, 3 & 5 from computer to pins 2, 3 & 7 on UIT for the RS232 cables. If you have no continuity check individual cables and connectors.
2. Verify computer comport by jumping pins 2 and 3 at back of computer while
running Windows Hyper-terminal Terminal.
3. With power off locate the jumpers on underside of the UIT board. Move the jumper
from pin 20 to pin 21 then power up the UIT. The UIT will run through a self
diagnostic program.
Motors Do Not Powerup
1. Verify Gantry is powered.
2. Remove cover from E-box and verify all amplifiers are powered and have a green
light.
3. Verify the motor power cables are connected. Continuity check the cables for
broken leads.
52
Form E-509
ELECTRICAL SCHEMATICS & PNUEMATIC DIAGRAM
The following electrical drawings are for reference only. Eastman maintains the right to change
electrical specification without notice. Any modification to machine wiring without written
permission from Eastman Machine Company shall void any warranties.
WARNING All electrical work should be performed by a trained technician familiar with
electrical lockout procedures. Electrical Boxes contain high voltage electricity
and can cause injury or death if proper precautions are not taken.
Form E-509
53
Pnuematic Diagram 31-9000-19
54
Form E-509
ELECTRICAL SCHEMATICS
Form E-509
31-9000-6 REV-C
Static Table
Sheet 1 of 4
55
31-9000-6 REV-C
Static Table
Sheet 2 of 4
Form E-509
56
31-9000-6 REV-C
Static Table
Sheet 3 of 4
Form E-509
57
31-9000-6 REV-C
Static Table
Sheet 4 of 4
Form E-509
58
31-9000-18
Diagnostic Cabinet
Form E-509
59
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising