ADA Auto Raster TM Pen Configuration Guide for EGX- 400/600 October 19, 2015 CONTENTS OVERVIEW GLOSSARY REQUIRED EQUIPMENT & ACCESSORIES o EGX-400/600 CONTENTS o AUTO RASTER TM ADA KIT CONTENTS o OTHER SETTING UP BRAILLE & CHARACTER CUTTER INSTALLING ZAD-600 VACUUM ADAPTER INSTALLING AUTO RASTER PEN o OLD PEN o NEW PEN INSTALLING & SETTING UP ENGRAVELAB EXPERT V9 o INSTALLATION o CREATING DRIVER COPIES Character Cutter Braille Drill Braille Pen PRODUCING ADA SIGNS Roland DGA Corporation 15363 Barranca Parkway Irvine, CA. 92618-2216 800.542.2307 949.727.2100 www.rolanddga.com Certified ISO 9001:2008
OVERVIEW The EGX-400/600 series of engravers combined with the Auto Raster - Pen from Accent Signage and EngraveLab Expert V9 software gives you a powerful tool set to begin creating ADA compliant Braille signage for use in all types of commercial properties. This document is designed to provide you with a speedy set of instructions to get your EGX-400/600 engraver producing as soon as possible. 2
GLOSSARY ADA-BUNDLE-MAN: Is the part number for the accessory kit that is included with the EGX- 350 ADA system. This kit includes the Accent manual insertion pen. ADA-BUNDLE-AUTO: Is the part number for the accessary kit that is included with the EGX- 400/600 ADA system. This kit includes the Accent manual insertion pen and the Accent auto insertion pen. Accent Raster Braille Method: A sign making system that is compliant with the ADA laws. It includes a process of drilling holes and then back filling the holes with raster beads that form raised braille characters for the visually impaired. Accent Raster Pen License Kit: This kit contains the license agreement between Accent Signage Systems and the sign maker. This license authorizes the sign make to use the Raster Braille Method. Accent Signage Systems: Owner of the Raster Braille Method and manufacturer of the Auto Raster pen ADA: American Disabilities Act Braille Drill: Also known as the braille dot cutter. The tool that is used to drill the holes that the raster beads press fit into. Character cutter: Also known as a.01 engraving tool, profile cutter. This tool is used for cutting around the pictogram and text that are raised components on the ADA compliant sign. EngraveLab Expert V9: Software that includes automatic conversion of text to grade II Braille. Used in the ADA sign production workflow. Engraving tool starter kit: A kit of engraving tools that includes.01,.015,.03 engraving tools, and DGK diamond scribe. Kit also includes a tool holder stand for organizing and storing said tools. Raised text, pictogram, and Braille. These are characters that are raised above the sign substrate surface by 1/32nd of an inch. US-CHIPSYS-C: Dust and chip collection vacuum that comes with the ADA-BUNDLE-MAN and ADA-BUNDLE-AUTO. It is used to collect cutting particulate during the engraving process. 3
REQUIRED EQUIPMENT & ACCESSORIES EGX-400/600 CONTENTS EGX-400/600 unit Operation panel (handy panel) Depth regulator nose unit (nose cone) 17mm spanner wrench 10mm spanner wrench 2mm hexagonal screw driver 3mm Allen wrench 11/64th th in solid collet AUTO RASTER TM ADA KIT CONTENTS CADLink Engravelab Expert Software V9 Accent Signage Auto Raster Pen Kit Rowmark Material Kit Aluminum spacer (acrylic in older kit) Plastic extenders (for use in older kit) US-CHIPSYS-C Chip Removal System ZAD-600 Vacuum Adapter Kit o Cable ties o 1.5mm Allen key o 5mm set screw AS-10 Adhesive Sheet 10 pack Bottom load, burnishing guide for EGX-400/600 11/64" character cutter with brass knob holder (requires spline wrench) 11/64" Raster Braille cutter with brass knob holder (requires spline wrench) Spline wrench for brass knobs on character and braille dot cutters OTHER Philips head screw driver (not included) Small zip ties (not included) Scrubbing brush (not included) 4
SETTING UP RASTER BRAILLE & CHARACTER CUTTER Turn the power switch located on the back panel of the unit to the on position. Turn the Emergency Stop (secondary power) switch clock-wise to power the unit on. The control panel will power on and display the model and boot version. Once completed the display will read HIT ENTER KEY. 5
Press the ENTER key to initialize the unit. Once the initialization is completed, the carriage will be located to the View position (Left rear). Place the adhesive sheet (AS-10) in the lower left corner of the table and place your ADA signage materials. Press the MENU key several times to make sure you are at the main screen where your current xyz coordinates are given. 6
Using the arrow keys on the control panel move the carriage so that the spindle unit is over the lower left corner of the material. Once the spindle is over the lower left corner of the material, press the XY ORIGIN SET button and press the ENTER key to set that as your origin point. Open the cover of the spindle unit to access the spindle assembly. 7
Remove the Raster Braille cutter tool from the cutter knob (brass knob) and install the cutter knob on the top of the spindle assembly. The brass knobs are counter-threaded, so tighten them using a counter clock-wise motion. Loosen the set screw on the cutter knob using a 3mm Allen key if needed. Install the solid 11/64 collet to the bottom of the spindle assembly and tighten it with the supplied spanner wrenches; 17mm on the bottom of spindle and 10mm on the collet. o NOTE: Do not use the spanner wrench on the Top Spindle Nut as you will damage the bearings if you loosen or tighten it. Install/tighten the nosecone onto the spindle assembly using a counter-clockwise motion until it stops. Then turn the nosecone clockwise 2 full turns (each full rotation consists of 25 clicks 8
or.025 inches in z height, each click is the equivalent of.001 inch) and set this as your zero position (you may need to mark the nosecone to indicate the 0 position later on). o NOTE: Be careful not to cross thread the nosecone to the spindle threads. Doing so will damage the spindle unit. Turn the nosecone clockwise an additional 42 clicks. Use your zero position mark to speed up this process (1 full rotation based on the zero mark is 25 clicks, then an additional 17 clicks). Each tick mark indicates a 0.001in change in height, so this will adjust the tool 0.042in, which is the depth for the Raster Braille cutter. Loosen the Z screw lock nut. This will allow the Z Axis to float. Using the arrow keys on the handy panel to move the nosecone over a flat area of the material. Place a flat plate under the nosecone and insert the Raster Braille cutter until it touches the plate. (bad picture, black glove and shadows blend, can t see the plate you are referring to) 9
Tighten the set screw in the brass knob to lock the cutting tool in position. This will zero the cutter to the proper cut depth for Braille production. Remove the brass cutter knob and Raster Braille cutter from the spindle as one piece using a clock-wise motion. Do not loosen the braille cutter from the brass knob. Rotate the nosecone counter clockwise 9 clicks which will adjust the depth to 0.033 for the character cutter. Using the same procedure to mechanically calibrate the Raster Braille cutter, remove the brass knob from the character cutter and tighten the brass knob onto the spindle. Again place a flat plate (or spanner wrench) under the nosecone and insert the character cutter until it touches the plate. Tighten the character cutter to the brass knob using the set screw. This will zero the cutter for the proper cut depth for cutting the pictograms and raised text. 10
Turn the nose cone counter-clockwise back 33 clicks to the original zero position. Both cutters are now configured for the proper depth and can be easily switched out by tightening/loosening the brass knobs to the spindle assembly. The Raster Braille cutter is set to.042 inch and the character cutter is set to.033 inch. 11
INSTALLING ZAD-600 VACUUM ADAPTER Detach the rubber caps at three locations and attach provided cable clips in their place. Install the vacuum ring attachment around nose cone making sure the ring is set level against the nose cone using upwards pressure. Orient ring so that set screw hole is facing forward. 12
Using provided 1.5mm Allen key, insert 5mm set screw into hole and tighten until set screw gives resistance. At this point the set screw should be just shy of flush with the vacuum ring attachment surface. o NOTE: Some older ADA kits will use a thumbscrew to secure the ZAD-600 vacuum ring. Arrange the hose and secure it in place with the previously installed cable clips. o NOTE: When you do this, move the spindle head over the entire work area to make sure the hose does not become bent, pulled, or snagged. Connect the duct adapter to the provided US-CHIPSYS-C vacuum. o NOTE: If the duct adapter does not mate flush with the vacuum then take steps such a wrapping the male hose component with PTFE (plumbers) tape or other material to obtain a close fit. 13
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INSTALLING AUTO RASTER PEN ATTACHMENT OLD PEN (Shipments before January 2015) Make sure that you have inserted sufficient Raster beads into the pen attachment either through using the included bead funnel or through some other means. 15
Using the Z+ key on the Control Panel, raise the Z Axis to its maximum clearance. Ensure that the cutout on the Auto Raster Pen mounting block is on the right Align the index pin on the Raster Pen with the opening located down the center of the spindle unit housing and ensure that the top of the Raster Pen block is flush with the spindle housing. Tighten the set screws using the provided 2mm hexagonal screw driver to attach the Raster Pen attachment to the spindle housing. Tighten the screws in an alternating fashion. 16
Make sure that the set screws on the left hand side of the Raster Pen mounting block are flush with the mounting block surface. Otherwise the spindle assembly might not be able to move freely in the z-axis due to tight clearances with the carriage. Use Phillips head screwdriver to remove the 2 screws that hold the cover latch plate to the housing. Remove the lower cable tie that holds the wiring harness to the carriage housing. 17
Rotate cable tie mount 180 degrees upwards and install new cable tie. This will allow for extra range of motion in the wiring harness. Install provided acrylic spacer between the latch plate and the motor. Use 3mm Allen key with provided screws to re-attach the latch plate. 18
To use the Raster Pen attachment, tighten the Z Axis screw. ss the MENU key multiple times until the OTHERS menu is displayed. Select the OTHER menu and press the ENTER key. Press the MENU key multiple times until the AUTO Z Control Menu is displayed. se the left/right arrow keys to select AUTO Z CONTROL - OFF and press the ENTER key. 19
Press the MENU key multiple times to get back to the default screen. Loosen the knob on the Raster pen and lower the knob to the bottom channel lock, then tighten the knob to lock the pen in place. Press the Z- key to lower the Raster Pen to the surface of the ADA sign substrate (the material into which raster beads will be inserted) so the spring compresses about 1/16 1/8 and set this as the Z Origin. 20
Remove the spindle housing cover and install plastic spacers at hinge points. This will allow you to close the spindle cover during engraving. 21
NEW PEN (Shipments on or after January 2015) Make sure that you have inserted sufficient Raster beads into the pen attachment either through using the included bead funnel or through some other means. Using the Z+ key on the Control Panel, raise the Z Axis to its maximum clearance. Ensure that the cutout on the Auto Raster Pen mounting block is on the right. 22
Before attaching the pen to the spindle assembly, check that the set screws on the left hand side of the pen are initially set flush with the interior surface of the mounting block. This will ensure that maximum clearance between the mounting block and the spindle assembly carriage is created allowing for unobstructed motion of the spindle along the z-axis. Tighten the set screws using the provided 2mm hexagonal screw driver to attach the Raster Pen attachment to the spindle housing. Tighten the screws in an alternating fashion. Double check that the set screws on the left hand side of the Raster Pen mounting block are flush with the mounting block surface. 23
Use Phillips head screwdriver to remove the 2 screws that hold the cover latch plate to the housing. Remove the lower cable tie that holds the wiring harness to the carriage housing. Rotate cable tie mount 180 degrees upwards and install new cable tie. This will allow for extra range of motion in the wiring harness. 24
Install provided aluminum spacer between the latch plate and the motor. Use 3mm Allen key with provided screws to re-attach the latch plate. To use the Raster Pen attachment, tighten the Z Axis screw. 25
Press the MENU key multiple times until the I/O, OTHERS, TEACHING, SELF menu is displayed. Select the OTHER menu and press the ENTER key. Press the MENU key multiple times until the AUTO Z Control Menu is displayed. Use the left/right arrow keys to select AUTO Z CONTROL - OFF and press the ENTER key. Press the MENU key multiple times until the REVOLUTION - Control Menu is displayed and press the ENTER key. Press the MENU key multiple times to get back to the default screen. 26
Loosen the knob on the Raster pen and lower the knob to the bottom channel lock, then tighten the knob to lock the pen in place. Press the Z- key to lower the Raster Pen to the surface of the ADA sign substrate (the material into which raster beads will be inserted) so the spring compresses about 1/16 1/8 and set this as the Z Origin. Once you are finished calibrating the z-axis for Raster Braille insertion, return the Raster Pen to the neutral position. 27
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INSTALLING & SETTING UP ENGRAVELAB EXPERT V9 INSTALLATION Begin a standard installation of EngraveLab Expert V9. Follow directions as prompted by Window s InstallShield Wizard. When you reach the Setup Type screen, choose the Complete EngraveLab Expert Installation. Choose I accept the terms of the license agreement on the next screen. On the Select Features screen, click on the Full Install button and continue as prompted. 29
When you reach the Cutting Devices screen, select the Yes, I would like to upgrade or install new cutting devices option and click Next. When you reach the Select the cutting devices you wish to update: screen, click on the Roland option (without checking the box) in the Manufacturer: field and choose the EGX- 400/600 option in the Output Device: field. Do not choose the EGX-400/600 Raster Braille options. o NOTE: Checking the Roland box first will prompt the InstallShield Wizard to select all Roland devices. For the purpose of this document we will choose the EGX-600 driver only. 30
Choose Continue when asked to install true type fonts on the next screen and continue with installation as prompted. Choose the EngraveLab Installer DVD as the location to install EngraveLab fonts and clipart from. Choose to copy your fonts and clipart to your hard drive for increased performance on the next screen and click OK. As indicated this may take some time. After navigating through a few more screens you will reach the InstallShield Wizard Complete screen. After clicking the Finish button you will now be done with installing EngraveLab Expert V9. 31
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CREATING DRIVER COPIES Creating separate drivers for the three different tools you will use (Raster Braille cutter, Auto Raster Pen, character cutter) for the ADA Raster Braille sign making process is a crucial step. This procedure will only have to be performed once for each tool. This procedure will make the ADA workflow simple to learn and simple to teach to new operators of the system. Open EngraveLab V9 and find the Engrave menu in the upper left hand ribbon on the home screen and choose Engraving Defaults from the drop down menu. Click on Setup in the Output dialogue box that pops up. Select the Roland EGX-400 or 600 driver from the Installed Drivers field in the Engraver Setup Window. 33
Select the Port tab and double check that the port location for the main driver matches the designated port in the EGX-400/600 driver found under Devices and Printers on your computer. This will ensure that all tool drivers created from this main driver will have the correct port setup. Click Apply once you have selected the correct port. Return to the Engraver tab and make sure that the Roland EGX-600 driver is still selected and click the Create custom copy of selected driver button beneath the Installed Drivers field. 34
Character Cutter A new window titled Create custom version of driver will prompt you to name your new driver. Type Character Cutter into the entry field and click OK. Click OK when you arrive back at the Engraver Setup window to return to the Output dialogue window. o In the Options field make sure that Sort and Output Tool Paths are checked. o In the Tool field, select Auto Z Enabled. o Under Smoothing make sure that High is selected. o Under Engrave make sure that Sign Plate and Selected are chosen. 35
Once all of the above parameters are set click Apply to confirm your changes. Now click on the Tool Options button at the bottom left hand corner of the Output window. A window with the name Character Cutter will appear. o Under the Tool field, make sure that Auto Z Enabled is again selected. o Set the Cut Velocity to 1.5 o Set the Plunge Velocity to 1 Click OK to return to the Output window. Once you are there click Apply to confirm all of your changes. Braille Drill 36
Click on the Setup button to return to the Engraver Setup window. Once again select the Roland EGX-400 or 600 driver and then click the Create custom copy of selected driver button. In the Create Custom Driver pop up window type Braille Drill into the entry field and click OK to return to Engraver Setup. Once you are back in Engraver Setup make sure that your new Braille Drill driver is selected in the Installed Drivers field and click OK to return to the Output window. Once you are in the Output window begin setting up parameters for the Braille Drill (these parameters will differ from those of the Character Cutter, though the process will be similar): o In the Options field make sure that Sort is selected. Do not select Output Tool Paths. o In the Tool field select Braille from the drop down menu. 37
o In the Smoothing field make sure that High is selected. o In the Engrave field select Sign Plate and Selected. o Under Object Start Point, select Current. Once all of the above parameters are set click Apply to confirm all of your changes. Now click on the Tool Options button at the bottom left hand corner of the Output window. A dialogue window with the name Braille Cutter will appear. o Under the Tool field, make sure that Braille is selected. o Set the Cut Velocity to 1.5 o Set the Braille Depth to -0.04 o Set the Plunge Velocity to 1.5 Click OK to return to the Output window. Once you are there click Apply to confirm all of your changes. 38
Braille Pen Click on the Setup button to return to the Engraver Setup window. Once again select the Roland EGX-400 or 600 driver and then click the Create custom copy of selected driver button. In the Create Custom Driver pop up window type Braille Pen into the entry field and click OK to return to Engraver Setup. Once you are back in Engraver Setup make sure that your new Braille Drill driver is selected in the Installed Drivers field and click OK to return to the Output window. Once you are in the Output window begin setting up parameters for the Braille Pen (these parameters will differ from those of the Braille Pen, though the process will be similar): 39
o In the Options field make sure that Sort is selected. Do not select Output Tool Paths. o In the Tool field select Braille from the drop down menu. o In the Smoothing field make sure that High is selected. o In the Engrave field select Sign Plate and Selected. o Under Object Start Point, select Current. o Under Move, set your x and y offsets for your Auto Raster Braille Pen. These coordinates will be based on the distance between the insertion tip of the Braille pen and the center axis of rotation of the spindle unit as measured from the tip of the nose cone. Standard values for these parameters are the following: X move = -0.3 Y move = 1.219 o NOTE: Due to differences between manufactured pens and the manual installation process the above measurements will not necessarily work for your setup. It is best to enter these values and then improve upon them through trial and error when actively inserting raster beads into pre-cut holes (this will be covered later). Once all of the above parameters are set click Apply to confirm all of your changes. 40
Now click on the Tool Options button at the bottom left hand corner of the Output window. A dialogue window with the name Braille Cutter will appear. o Under the Tool field, make sure that Braille is selected. o Set the Cut Velocity to 1.5 o Set the Braille Depth to -0.04 o Set the Plunge Velocity to 1.5 Click OK to return to the Output window. Once you are there click Apply to confirm all of your changes and then click the Close button. You are now finished with creating your tool drivers. 41
PRODUCING ADA SIGNS Launch EngraveLab Expert V9. You will be prompted with the Plate Size dialogue box where you will be able to setup the desired parameters for your sign. In this case we will use standard settings for an 8in x 8in sign. Click OK to continue. Import the file for the ADA sign that you wish to create. o NOTE: Setup Braille job in accordance with ADA Laws, guidelines and regulations. Please refer to software documentation for generating Braille data. A compliance reference guide also comes with the Accent Signage Raster Braille Kit, (three ring binder) 42
Once you have imported your file, EngraveLab will give you a notification in the bottom-left hand corner of the program window that says Seeking Place For Import. You will also notice that your mouse has turned into a bracket. Click and drag this bracket over the black 8in x 8in square and then release to locate your file in the square. Resize and locate the vector image as needed. Once you vector image is correctly placed, click and drag your mouse over the image again to make sure that it is selected (you will know that your vector images are correctly selected when they show as a blue outline). 43
Go to Engrave > Create Tool Path and select Male to create all tool paths for your sign. Click OK when the Male dialogue box appears to continue. Go to Engraving Defaults and select the Braille Drill from the Selected Driver dropdown menu. Click Apply and Close to continue. 44
Install the Raster Braille cutter into the spindle assembly. Turn on the attached vacuum unit in preparation for cutting. Select the Braille portion of your vector image and create a tool path for it by navigating through Engrave > Create Tool Path > Drill Center. Go to Engrave > Output or use the hot key combo Alt + P to bring up the Cut Toolbox ribbon. Click on the Engrave button on the far right side of the ribbon to output your tool path to the engraver. o NOTE: Close the cover to the spindle assembly before cutting. Otherwise the machine might not let you continue. 45
Once the Braille cutter has created holes for the Raster beads, turn off the vacuum unit. Begin configuring the Raster Pen attachment. Adjust the pen to full lowered position. Put the z-axis into locked position. 46
Once again visit Engraving Defaults and make sure that the Braille Pen driver has been selected and applied. Navigate to the OTHERS menu on the handy panel and set both REVOLUTION and AUTO Z CONTROL to OFF. Hit Alt + P to bring up the Cut Toolbox ribbon and click the engrave button. The engraver will attempt to insert the Raster Braille beads into the pre-drilled holes using the pen attachment, but it is likely that you will have to adjust the x and y offsets for your Braille Pen driver in the Output window under Engraving Defaults several times before you are successful in doing this. o NOTE: A positive increment in the x move field will adjust the pen s position to the right. Similarly, a positive increment in the y move field will adjusts the pen s position upward. Try correcting for one axis at a time through repeated output cycles. In some instances the pen may jam up with beads while attempting to insert them during the x and y adjustment process. To correct this problem try manually discharging beads through the pen until the any jams are removed. 47
Once you have seen the engraver successfully insert beads into the Braille substrate, run your fingers over them to make sure that the fit is secure. If any beads come loose try to adjust the x and y offsets again until the pen inserts beads with a snug fit on the first try. Now configure the engraver for the character cutter (physical tool). Put the z-axis into floating position. Remove the Raster Braille cutter from the spindle assembly and install the character cutter. Return the Braille Pen to the neutral position. 48
Navigate to the OTHERS menu in the handy panel and set REVOLUTION and AUTO Z CONTROL to ON. Turn on the vacuum unit that is attached to the ZAD-600 vacuum ring in preparation for cutting. Go into Engraving Defaults and select the Character Cutter driver from the drop down menu in the Output window. Click Apply and Close to continue. Select all vector images that will be cut out with the character cutter and make sure that a tool path is created using the Male option in the Create Tool Path drop down menu. Hit Alt+P to bring up the Cut Toolbox ribbon and hit the Engrave button at the far right to output your latest toolpath. Once the engraver has finished running the toolpath for the character cutter, turn off the vacuum unit. Carefully peel back the top layer of unwanted material on your sign. 49
Use a course brush to clean away any excess cuttings not cleared away during the cutting process by the vacuum adapter. Remove the character cutter from the spindle assembly and use the tip of the tool to pry out any remaining pieces of unwanted material (other prying tools can be used for this process). Your sign is now complete! Carefully peal the sign away from AS-10 sheets on the engraving bed and prepare your machine for its next job. 50
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