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1. To enable or disable Japanese sun See page 53 step 45 To enable or disable the entry of decimals See page 53 step 46 To see the next options screen press OPTIONS or 3 59 17 18 MOTOR METERS Power meter Front cut Next screen OR MOTOR METERS Auto eject Distance Next screen OR 1 ON ON 1 ON ON To enable or disable the power meter display See page 53 step 47 To enable or disable display of the length of paper to be sheared off See page 54 step 48 To see the next options screen press OPTIONS or 3 To enable or disable the automatic stock eject after a cut before driving backwards See page 54 step 49 To adjust the distance of the auto eject See page 54 step 50 To return to MANUAL MODE press OPTIONS or 3 microcut 60 service manual microcut is designed to be very easy to service and maintain In general if complications arise in the computer try turning the power off and back on to see if things straighten out automatically If this occurs frequently more than once a year excluding thunder storms the AC power should be checked Refer to the WIRING section in this manual Connections on the display console or electrical problems within the machine itself could also be at fault Plug all connectors in and out a few times to make sure they are clean Refer to the MAINTENANCE section in this manual 61
2. B STATUS SCREEN 4 52 1 MANUAL MODE acceleration rate 2 AUTOMATIC MODE acceleration rate deceleration rate STATUS SCREEN 1 1 false clamp status 2 calibrate gauge STATUS SCREEN 5 1 backlash correction value 2 allow reverse drive with the clamp down KNIFE STATUS 1 cut strokes on this blade 2 last knife change date STATUS SCREEN 6 1 settling tolerance 2 auto correction JOB MEMORY 1 locations used 2 locations left STATUS SCREEN 6 1 true or fake position 2 final digit on or off Are the Programmed machine sizes correct UNITS STATUS 1 inch display enabled 2 Fractional display enabled ENTER SERVICE CODE for ADVANCED MANUAL MODE OPTIONS UNITS STATUS 1 centimeters enabled 2 Millimeters enabled UNITS STATUS 1 Japanese sun enabled 2 Left decimal may only whole numbers be used MOTOR METERS 1 display power meter 2 Display cut length in front of the knife STATUS SCREEN 1 auto eject on or off 2 auto eject distance MANUAL MODE OPTIONS DETAILS 87 312 in MANUAL MODE Job 1 Cut 1 Press MANUAL to ensure that the computer is in MANUAL MODE MANUAL 87 312 in MANUAL MODE Job 1 Cut 1 Select language 1 English Espanol Other OPTIONS OR STATUS SCREEN 1 False clamp ON Calibrate gauge Next screen 2 Press OPTIONS to access the MANUAL MODE
3. Follow procedure all the way through DO NOT TURN POWER OFF PROGRAMMING PROMPTS Cut positions available Out of memory Job already used Searching last job End of search Job not found Not enough memory The SET UP ROUTINE must be fully completed before continuing This prompt warns the operator of remaining job memory space if that space is less than 100 positions All of the available job memory has been used Note that while microcut has the option for an almost infinite selection of job numbers each job may take up several of the available memory locations The memory space will be used up before all job numbers are programmed Delete some of the unused or seldom used jobs to make room for the new ones The new job number that has been manually selected is already used It will be necessary to choose a different number or erase this number before programming microcut is looking for the last programmed job while in the REVIEW MODE microcut has shown all of the programmed jobs while in the REVIEW MODE microcut was not able to locate the requested job in memory microcut does not have enough unused job memory available to program the number of stops requested in either the LABEL MODE or SHEET DIVIDE ROUTINE 68 The job in use has been code protected to prevent Operator access code anyone from changing or deleting it Refer to required to modify PROGRAMMING OPTIONS in thi
4. X Refit the display cover and tighten the Phillips screws on both sides ss 18 Microcut Display Console Sigeal for optional motor brake False clamp sense line Knife sense line Clamp sense line Position sense line Note The four sensing switches can be installed in any order Green wire Ground A Black wire Relay control lines VAC phase 12 V DC coils White wire VAC phase microcut DC Drive Motor Pin 1 110 V AC 12 VDC AC Pin 2 Neutral Power Supply Power Input Bets rer microcut Isolation Transformer amp DC Power Supply JUMPER CONFIGURATION FOR EARLY STYLE TRANSFORMERS model s lower than XL1036 180 V AC to 250 V AC 1 to 2 and 3 to 4 19 microcut is equipped with control lines which can be used to activate relays that control the air table and original equipment brake X These must have 12V DC coils requiring no more than 250 mA for operation lt Check current requirements of the circuit being controlled to specify the contact current rating X Mount the relay s inside the original equipment control panel The normally open contacts may then be wired to control these operations on the machine X The coils of the DC relays will be wired into the extra terminal on the display console Auxiliary Control Line Connector Pin Out 3 pin mini Phoenix 3 pin Phoenix or 7 pin Phoenix type connector wiring
5. During thunderstorms or in the event of some severe electrical disturbance it is possible for any computer to lose track of itself If such a failure occurs turning the power off and then back on should correct it BASIC TROUBLESHOOTING The microcut display console houses three printed circuit boards the CPU board the keyboard and the vacuum fluorescent display In general these parts are not user serviceable The display console has been designed with a universal mount and plug in connecting cables so that it is very easily removed If trouble arises follow these steps to identify the source problem then contact your microcut dealer or GMS for further assistance 1 If there are any lights on at the VF display then go to step 2 a If there is 12 V DC coming into the console at the 2 pin Phoenix connector then go to section 2 If not then i Check the connections to the power supply ii If good AC voltage is coming into the power supply replace the 12 V DC power supply board in the transformer 2 Ifthe display asks for a language selection then go to step 3 If not then a Ifthe screen only shows one blinking square cursor in the top left corner of the display replace the display side 80535 microcontroller b Ifthe display shows the key test routine check for a stuck lt gt key c Ifthe unit beeps like it is working despite the blank screen replace the screen d Repair or replace the console 3 Ifthe keys resp
6. Restart required Position sense error The main computer has not powered up properly Turn power off and count to ten Try turning power on again Service may be required Try turning the power off and on again Service is probably required Memory pertaining to the type of cutter microcut is installed on has been lost It will be necessary to go through the SET UP ROUTINE to correct this A key appears to be pressed in during the start up procedure Refer to TESTING THE KEYBOARD to verify which key this is The data that allows microcut to operate on this machine has been damaged It will be necessary to go through the SET UP ROUTINE to reprogram this information microcut has been told to stop or it has completed a routine which requires a full restart to recalibrate Turn the power off then back on and press lt AUTOMATIC gt to start Either the backgauge is tripping the position sensor at the beginning of the setup routine or microcut has detected that the position sensor has been tripped for much too long a distance while moving forward This error may occur during initialization when power is first turned on if microcut has to move forward more than a few inches to untrip the position switch If this is the case then turn the power off and restart normally This check prevents microcut from running into the front of the cutter if the sensor was not connected or had become damaged 67 INCOMPLETE SETUP
7. AUTOMATIC as though the cutter is ready for use Instead press OPTIONS Press 2 to enter the SET UP ROUTINE This memory test is nondestructive so press YES 35 9 Save memory YES or NO 10 Erase memory YES or NO 11 Select Units Inches Metric Sun Japanese OR If this is a new installation or if contaminated memory is a suspected problem press NO If the job memory is valid and not to be erased press YES This example will erase the memory If the memory is to be erased press YES Select the units desired This example will press 1 for inches or 2 for metric 36 12 13 14 Move the gauge one inch does the drive motor turn between 3 and 6 full turns CLAMP SWITCH CHECK CUT SENSING SWITCH Is switch installed to sense the cycling of the knife Move the backgauge one inch 25 mm while watching the motor pulley The pulley must turn at least 3 but not more than 6 turns Press lt YES gt when the turns ratio is verified lt Less than 3 will cause excessive current draw greater than 6 will sacrifice high speed drive either will cause settling problems Adjust or change the pulley if necessary If the Clamp Sensor is properly installed and the clamp is in the up position press YES lt The computer will then verify the Clamp Up Sensor signal and either continue the SET UP ROUTINE
8. b Enter the correct current position of the backgauge If the correct value cannot be entered check to be certain that i The maximum rear value is greater than the position sense location and ii The position sense location is greater than the maximum rear value minus 10 encoder turns 9 Ifthe backgauge drives in high speed go to step 10 If not then a b c d e f g Be certain that the high speed value programmed in the SET UP ROUTINE is high enough Adjust this in the MANUAL MODE OPTIONS routine if necessary Be certain that the clamp up sense is not covered Be certain that the motor turns at least 3 times but not more than 6 times for each inch of backgauge travel Check for a bind in the backgauge i Static bound when stationary or at low speed ii Dynamic bound when moving at high speed iii Check motor current draw via the built in power meter or a current meter Be certain that the transformer is connected to the correct AC input voltage Be certain that the correct motor was used for this size machine Contact GMS for details If the voltage being supplied to the motor during drive is less than 80 V DC replace the display console 10 If the backgauge positions to the target location correctly go to step 10 If not then a b c d e f g Be certain that the motor turns at least 3 and not more than 6 revolutions for one inch 25 mm of backgauge movement Make sure that
9. 19 Enter forward reference point 40 May only whole numbers be entered 20 Enter max rear 41 Display power meter 21 Enter false clamp width 42 Display cut length in front of the knife 22 Enter minimum front position 43 Auto eject on or off 23 Are the programmed machine sizes 44 Auto eject distance carrect 33 Sample SET UP ROUTINE Before beginning the SET UP ROUTINE be certain that the backgauge is somewhere in the middle of the table not near the front or rear of the cutter r TURN ON POWER 2 Select language 1 English Espanol Other OPTIONS D OR 3 Are all guards in place 3 Is daily lubrication completed Select the language desired by pointing to the correct selection and pressing YES Make sure all guards are in place Inspect the machine to ensure proper and safe operation then press YES The leadscrew should be lubricated with light machine oil and fluid levels and routine cleaning should be performed on the machine at this time Press YES when completed 34 Is everyone clear of the machine Press the AUTOMATIC key to calibrate OPTIONS Demonstration Calibration amp test Previous screen Test memory YES or NO Look around the machine to make sure that no one is near any of the moving parts and that nothing has been left on the table surface which could be damaged Press YES to continue Do not press
10. 30 Enter the maximum speed that the backgauge will Fast gauge speed is travel in AUTOMATIC or SEMI AUTOMATIC 43 Inches per second MODE lt microcut will not allow a speed to be entered that is greater than about one fifth the length of the table lt Backgauge speed should be set so that the computer just barely beats the operator to the next cutting position Excessive speed serves no purpose but to wear out the machinery prematurely This example will use 5 inch 12 7 cm 31 Enter the speed of the backgauge when the slow Slow gauge speed is drive is requested using the arrow keys See inches per second MANUAL MODE OPERATION lt Slow gauge speed is purely a matter of operator preference lt If the operator prefers very slow controlled adjustments when using the arrow keys enter a small number If more rapid adjustments are desired enter a larger number This value does not affect automatic operation in any way This example will use 1 inch per second 2 54 cm 32 Enter MANUAL MODE ACCELERATION In MANUAL MODE the Acceleration rate is 44 percent of maximum rate PERCENTAGE lt How fast does the computer have to accelerate to reach the programmed maximum speed when the arrow keys are used in MANUAL MODE lt Any percentage is legal Some operators prefer very fine control and enter 1 others want a quick response and choose 80 This example will use 50 the Acceleration
11. Air control return Pins 5 6 amp 7 Original equipment operations AKO AKE CD lt Pin 1 is the pin which is closest to the sensor cable inputs lt On some units the connector will only offer the first three connections AIR CONTROL pin 1 Provides a current path ground for the coil ofa relay that disables the air table whenever microcut is commanding high speed forward drive or when the clamp is lowered BRAKE CONTROL pin 2 Provides a current path ground for the coil of a relay that disengages an original equipment brake when backgauge drive is requested lt A bypass switch on the brake line may be desired to allow the back gauge to be moved manually POSITIVE COIL VOLTAGE pin 3 Provides 12 V DC to the relay coils X An optional relay board assembly is available from GMS if the parts are not available locally 20 microcut operation manual 22 If the SET UP ROUTINE has not ever been performed on this computer proceed to the SET UP ROUTINE section in this manual After the SET UP ROUTINE has been performed on the computer it is able to recalibrate itself automatically in the START UP ROUTINE each time power is turned on The display consists of four lines In normal operation Line 1 displays the current backgauge position 45 000 inches 45 000 inches MANUAL MODE Line 2 displays the operating status mode Job 1 Cut 9 L MANUAL MODE 33 575 Line 3 displays the current job
12. Drive error KNIFE DOWN No motion seen FAILURE RECOGNIZED 110 VAC power missing Check transformer microcut was not in position when the knife was activated microcut will show this display whenever the cut sensor indicates the knife is in the down position The gauge has moved in the wrong direction for too long Try again or go through the SET UP ROUTINE microcut has not detected any motion during a period of time when the backgauge should have been moving Either the backgauge was not moving or the computer did not correctly detect the motion If the backgauge moves a bit and then stops microcut is not seeing the motion and has a counting problem See SERVICE AND TROUBLESHOOTING If no motion occurs then microcut is suffering from a drive error microcut has not sensed 115 V AC for the drive 70 circuit Either the external thermal breaker on the transformer has popped a connection from the transformer to the display has come loose or the AC sensing circuit in the computer is not operational FAILURE RECOGNIZED Possible AC input line noise or the AC sensing circuit AC and AC occurred in the computer is not operational at the same time Check line spikes FAILURE RECOGNIZED Microcut has not sensed the AC power line correctly False zero detection Service acvordinely on the AC power line Check brown outs FAILURE RECOGNIZED A power disturbance has caused a data error in the Over voltage sta
13. OPTIONS ROUTINE Select the language desired lt Other languages are available by pressing 3 or OPTIONS STATUS SCREEN 1 A microcut will display the status of the false Paper clamp lt ON or OFF will be displayed based on the status of the False Paper Clamp Sensor 54 If the backgauge position is inaccurate by a uniform amount at every position on the table press 2 to enter the CALIBRATE GAUGE routine This routine can only correct for an error in absolute backgauge calibration i e if the calibration is off by 1 inch up front 1 inch in the middle and 1 inch at the rear this routine can resolve it If the inaccuracy is different at different places on the table i e 1 inch short up front inch short in the middle and 4 inch long in the back then the leadscrew pitch is incorrectly programmed and the entire SET UP ROUTINE must be completed This routine will not allow enormous adjustments Depending on the original installation these adjustments should be able to compensate for at least 4 65 cm but never more than 5 12 7 cm To access the next options screen press OPTIONS or 3 OR KNIFE STATUS 2 KNIFE STATUS SRESHLORYS 9099 A CUT STROKES Displays the number of cuts since microcut was last informed of a knife change Changed Next screen B CHANGED Displays the last date that microcut was informed of a knife change Press YES to
14. and cut number Line 4 displays the current target position O 33 575 lt Line 4 also displays the current machine status i e KNIFE DOWN or CLAMP DOWN To manually drive the back gauge to position use the UP and DOWN arrow keys See MANUAL MODE OPERATION To move to a precise location type in the measurement and press MOVE See MANUAL MODE OPERATION To program a series of stop points load points and push outs so that a sequence job can repeatedly be run automatically program a job See PROGRAMMING A JOB lt The jobs can be modified to correct for errors or make changes lt Jobs are saved in memory so that they can be recalled when needed again Any options that are relevant to the function currently being performed are accessible by pressing OPTIONS To select an option being displayed on the screen press UP or DOWN arrow to point to the correct selection and then press YES or enter the line number desired Press UNITS to change the readout to inches metric or Japanese sun 23 1 TURN ON POWER Select the language desired and press YES English Espanol Other OPTIONS Make sure all mechanical guards are in place Inspect the machine to ensure proper and safe operation then press YES The leadscrew should be lubricated with light machine oil fluid levels should be checked and routine cleaning should be performed on the machine at this time Press YES when com
15. backgauge drive control panel Other cutters may also require that the brake be disabled or the drive clutch enabled Polar remove the wires going to the brake at the junction block under the back of the table Harris remove the magnetic spacer control fuse Lawson label remove and tape the wires jumper the OE reverse drive key lt Make sure that all wires are properly insulated lt Mechanical methods may be preferred over electrical for locking clutches or disabling brakes 13 Isolation Transformer The transformer converts two hot AC phases to 110V AC and 12 V DC X X This insures reliable operation when microcut is wired directly to 3 phase power Install this near the machine power inlet or the 3 phase switched power contacts so that the AC INPUT cable is able to reach the connection point refer to WIRING AND POWER lt The board that the transformer is shipped on works well as a template to mark the holes but should NOT be used to mount the transformer lt Wiring is discussed in detail in the WIRING AND POWER section of this manual Proximity Sensors Proximity sensors monitor the status of the machine X X Each sensor has a label indicating its purpose Each sensor must be installed according to its designation An LED on each sensor indicates when it detects metal within 0 1 inches 2 mm of the face of the sensor barrel Use any combination of brackets hardware and dou
16. backlash from entering the measurement 39 22 Use the DOWN ARROW To move the gauge to Within 10 inches of the knife 23 NCAUTION Drive is operator controlled Avoid collisions This example will use 43 inches 110cm Move the backgauge by pressing the Down arrow key until the gauge is within 10 inches 25cm of the knife being careful not to drive the backgauge into the clamp lt BE CAREFUL The backgauge is under the control of the operator and damage to the machine and human injury are depending on operator caution 40 24 Is the backgauge less than 10 inches from the knife YES or NO When the key is released the display will read IS THE BACKGAUGE LESS THAN 10 INCHES 25 cm FROM THE KNIFE Press YES if it is If not press the NO key and microcut will return to the forward drive routine step 22 Turn the handwheel forward until the backgauge is at an exact unit value Type the exact current position and then press YES lt microcut uses the reference positions to calculate the leadscrew pitch and calibration values These positions must be as accurate as possible or microcut will not be able to position the backgauge accurately microcut requires that these values be whole numbers with no fractional component Use the handwheel to position the gauge accurately before entering the value Move the handwheel To an even val
17. been shown that installations can be simple and call backs for repairs and make rights few Please report any problems or suggestions to the factory GRAPHIC MACHINERY amp SYSTEMS A DIVISION OF GOLDEN GATE MICROSYSTEMS INC 30 Golden Gate Drive San Rafael Ca 94901 Tel 415 457 7500 Fax 415 457 1694 e mail sales graphicmachinery com http www graphicmachinery com This includes but is not limited to packing parts supplied design and quality of parts and assemblies and anything else that may affect the ease of installation and use of this product in a productive professional manner THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION WHICH IS PROTECTED BY COPYRIGHT ALL RIGHTS ARE RESERVED NO PART OF THIS DOCUMENT MAY BE PHOTOCOPIED REPRODUCED OR TRANSLATED TO ANOTHER LANGUAGE WITHOUT THE PRIOR WRITTEN CONSENT OF GRAPHIC MACHINERY amp SYSTEMS microcut is a registered trade mark of golden gate microsystems inc Serial Number O pte Cutter Brand e Installed by gt microcut installation manual microcut can be installed on any type of guillotine paper cutter Installation is easier on machines which use a leadscrew for backgauge movement Other methods of backgauge movement such as chain or cable drive cannot assure the accuracy or positioning speed of microcut and it is suggested that either a leadscrew kit be installed or that the machine be replaced microcut IS NOT INTENDED TO CONTROL THE KNIF
18. cm LLOC 36 CLAMP DRIVE CONTROL May the computer drive the backgauge toward the Allow reverse dive rear of the cutter even when the clamp is still down With clamp down f f YES or NO lt The computer will never drive the backgauge forward when the clamp is down but often backwards drive is acceptable while it is still down YES 46 37 Enter the desired settling accuracy In AUTOMATIC MODE How far can gauge be Knocked out by lt How close to the mark must the backgauge be 000 in before the computer stops attempting to perfect it The computer will try to position with zero error every time but a smaller number here may cause the computer to take longer when settling on the mark if the cutter has any mechanical irregularities lt Considering the fact that a human hair is about 004 010 cm wide this parameter is often set between 002 008 005 cm 020 cm This example will use 005 013cm 38 In AUTOMATIC MODE Auto correction on or off If gauge knocked out of f Press YES if the backgauge should correct its Position gauge will Me ee Recorrect YES or NO position if it is knocked out of tolerance while in AUTOMATIC MODE If not press NO 39 In AUTOMATIC MODE Select actual or artificially perfect position display Do you want to see the ve True position lt A YES here will allow the true position of YES or NO the backgauge to be display
19. for each inch 25 mm of backgauge movement lt This may be the second most common error that novice installers commit Having an incorrect motor turns ratio can cause speed problems settling difficulties and cause premature wear to the machinery motor cabling and computer If possible it is convenient to mount the microcut motor so that it lines up with the existing leadscrew drive pulley lt In many cases the same belt can be used for the new motor as was used for the original equipment drive This offers a second advantage in that when only one drive belt exists only one drive system can be attached to the leadscrew at a time If the motor mounting method does not isolate the original drive system other means will be required Keep the drive belt LOOSE to insure smoothest operation lt Too much motor belt tension can cause settling problems DO NOT USE ADJUSTABLE LINK BELT AS A PERMANENT DRIVE BELT If microcut is ordered for a Schneider type cutter a one inch wide cogged belt pulley will be included with the kit This allows microcut to drive with the original flat belt Original motor will need to be removed lt Make sure wires are labeled and taped The brake will have to be disabled and the drive clutch enabled to allow proper operation lt This can often be done by flipping the wires between the clutch and brake The motor plate may need to be spaced down slightly to avoid conflict with the original equipment
20. inform microcut that the knife has been changed To access the next options screen press OPTIONS or 3 O JOB MEMORY 3 JOB MEMORY Locations used 57 Locations left 1943 A LOCATIONS USED Displays the amount sNextscr ti of memory that has been used B LOCATIONS LEFT Displays the amount of memory that is still available To see the next options screen press OPTIONS or 3 OPTIONS 3 55 OR MACHINE SIZES MACHINE SIZES AS COO in Maximi A Extreme rear position that the backgauge may reach maximum table length 3 000 in Clamp 1 000 in Minimum lt How far back can the backgauge travel before running Minimum cutting length with false paper clamp installed How far forward can the backgauge travel before running into the false paper clamp The false paper clamp is a smooth metal plate that may be attached to the paper clamp when clamping delicate stock Minimum cutting length with false paper clamp removed How far forward can the backgauge travel before running into the clamp when the false paper clamp is removed The false paper clamp is a smooth metal plate that may be attached to the paper clamp when clamping delicate stock If the programmed machine sizes are incorrect the complete SET UP ROUTINE must be executed To access the next options screen press OPTIONS Further options are available only with the authorized Please enter your servic
21. is possible to resolve field issues over the phone to minimize down time and maximize productivity When calling for service please have this manual on hand and the serial number from the back of the display console to help us resolve your concerns expeditiously If factory service is required please contact us for specific return directions photocopy and complete the return form on the following page lt The more information that you provide with the return the more effective our service will be GMS GRAPHIC MACHINERY amp SYSTEMS A DIVISION OF GOLDEN GATE MICROSYSTEMS INC 30 Golden Gate Drive San Rafael Ca 94901 Tel 415 457 7500 Fax 415 457 1694 e mail service graphicmachinery com http www graphicmachinery com T77 MICROCUT REPAIR RETURN AUTHORIZATION SHEET RMA SENDER Compan Street fey Woo O Phone Number Fax Number Contact name Purchase Order Number List all parts being shipped Symptoms Instructions 78 sec esha ve ya Povey a 2 day BLUE a 3 day ORANGE Ef Ground BROWN All repairs MUST be accompanied by this sheet Only repairs shipped overnight or couriered and received by 10 30 AM are eligible for single day repair 30 Golden Gate Drive San Rafael CA 94901 415 457 7500 fax 457 1694 Signed 79
22. on in step 49 how far should auto eject movement the stock be pushed Should be In lt This answer will have no bearing on microcut s ability to determine where the end of the table is The computer knows better than to run into the clamp when it is near the front of the table lt Additionally microcut will not allow an auto eject to be programmed that is greater than 15 inches This helps prevent microcut from pushing a large pile of paper off the front of the operator s table This example will use 5 12 7cm VLLL Si Memory test In progress The SET UP ROUTINE is complete The computer will now exit to MANUAL MODE and be ready for use Many of the user definable options that are programmed in the SET UP ROUTINE may be changed in the MANUAL MODE OPTIONS routine The first few options may be changed simply by accessing the first few screens but the ADVANCED MANUAL MODE OPTIONS may only be changed by persons possessing the authorized service code The following page is a brief summation of the variables that may be altered in the MANUAL 51 MODE OPTIONS The subsequent pages offer a detailed step by step explanation of the variables found in the MANUAL MODE OPTIONS l Enter the MANUAL MODE ADVANCED MANUAL MODE OPTIONS 2 Press OPTIONS to proceed from y each of the following screens to the next 3 SELECT LANGUAGE A STATUS SCREEN 3 1 Fast gauge speed 2 Slow gauge speed
23. reprogrammed to operate on another cutter or test fixture as after repair lt Every microcut display is identical regardless of the machine it is installed upon The SET UP ROUTINE allows calibration to any machine The following page is a brief summation of the SET UP ROUTINE The subsequent pages offer a detailed step by step sample SET UP ROUTINE 32 Turn on power ADVANCED MANUAL MODE OPTIONS FROM THIS POINT ON 2 Select language Y 3 Are all guards in place 24 Enter fast gauge speed 4 Is daily lubrication complete 25 Enter slow gauge speed 5 Is everyone clear of the machine 26 MANUAL MODE acceleration rate 6 Press OPTIONS 27 AUTOMATIC MODE acceleration rate 7 Select SET UP ROUTINE 28 Deceleration rate 8 Test memory 29 Backlash correction value 9 Erase memory 30 Allow reverse drive with the clamp down 10 Select units 31 Enter settling tolerance 11 Check motor turns ratio 32 Auto correction on or off 12 Clamp sensor check 33 True or fake position 13 Cut sensor installed 34 0 000 or only 0 00 to be displayed 14 Cut sensor check 35 Inch display enabled 15 Is the back gauge at least 10 from the rear 36 Fractional display enabled 16 Motor direction test 37 Centimeters enabled 17 Enter rear reference point 38 Millimeters enabled 18 Drive back gauge to lt 10 39 Japanese Sun enabled
24. 4 The paper cutter should be placed away from distractions water coolers break room main passages traffic open doors etc 5 The floor should be able to support the weight of the paper cutter in a level position without excessive vibration 6 The paper cutter must have enough space around it to allow the operator access for lubrication and maintenance Space should be supplied for storage of tools lubricants spare knives cutting sticks and other equipment 7 Rails should be placed around the machine to prevent unauthorized or incidental entry into the cutter work area 8 The addition of microcut may require modification to existing guards or addition of new ones DO NOT operate microcut until guards are installed to prevent accidental contact with any moving object Providing proper guarding and insuring that this guarding is installed is the responsibility of the owner and not of the manufacturer or distributor of microcut While reasonable efforts have been taken in the preparation of this manual to assure its accuracy the manufacturer and distributor assume no liability resulting from any errors or omissions in this manual or from the use of the information contained herein Specifications and software are subject to change without notice For additional information on safety please contact your local safety authority Everything safely possible has been done to ease the installation of microcut With proper care it has
25. E OR THE CLAMP ON THE PAPER CUTTER Anything dealing with the clamp or knife is not to be tampered with or adjusted during the installation or operation of microcut Any alterations to the knife or clamp safeties circuits or operation or any installation technique which compromises the safety of anyone working on or around the machine is STRICTLY FORBIDDEN GUARDING MAY NEED TO BE ALTERED OR ADDED to offer proper protection when microcut s parts and assemblies are added to the machine This must be done before microcut is operated Never operate the machine until all guarding is complete A moving parts and hazards must be covered in such a way as to prevent accidental contact of any sort The installation is basically mechanical It involves mounting the display console containing all of the electronic controls the DC motor to drive the backgauge the shaft encoder to signal backgauge movement to the computer four sensing switches to inform the computer of the machine status clamp knife false clamp and position and a transformer which allows 3 phase power to be used to power the computers and motor drive The cables are plug in type Several photos are included at the back of this manual for mounting technique reference microcut is a retrofit system so every installation is unique Install the components for function as well as fit The brackets are designed with many extra holes and slots They are easily modified and can be adapted
26. ET UP ROUTINE b Check the connections to the encoder Particularly the female female RJ45 connector c Replace encoder Cable connections can fail due to contamination Keep the cable ends away from dirt and oil etc when they are not connected Sometimes a connection problem here can be cured just by removing the connector and putting it back on a few times The sliding action of the pins can help self clean them It is a good idea to insert and remove the cables a few times at the time of installation NEVER use contact cleaners on the cables sensors or encoder Many contact cleaners will attack the polycarbonate portions of these parts 13 If the unit does not suffer from electrical noise in general go to step 14 If it does then a Check the following i All connections ii Earth ground connection to machine iii Possible ground loops isolate the transformer first then the display then the motor case ground iv Make sure that the microcut cables do not run near other cables v Replace the display 12 V DC supply encoder or cables 14 If the unit cuts accurately go to step 15 If not then a Cut the end from a piece of stock b Rotate the stock 180E c Cut the stock so that it is an even length i e 22 35 81 100 cm 1200 mm etc d Cut the stock in even increments i e if the stock is 35 cut it at 30 25 20 15 10 and 5 e Stack the strips in a pile and observe the pattern i Ifall strips ar
27. ary OR 20 The backgauge will now move toward the rear of the Calibration routine machine to trip the Rear Position Sensor Please wait lt It is imperative that the position sensor is adjusted properly so the gauge will stop before hitting the rear of the machine See MECHANICAL INSTALLATION Proximity Sensors lt If the backgauge bumps into the rear press any key to return to the beginning of the START UP ROUTINE Check the LED indicator on the position sensor and adjust as needed and begin the SET UP ROUTINE over again 21 Turn the handwheel forward until the backgauge is at an exact unit value Type the exact current position and then press YES Move the handwheel To an even value This position is 000 inches EXACTLY lt microcut uses the reference positions to calculate the leadscrew pitch and calibration values These positions must be as accurate as possible or microcut will not be able to position the backgauge accurately lt microcut requires that these values be whole numbers with no fractional component Use the handwheel to position the gauge accurately before entering the value lt When turning the handwheel to move the backgauge to an exact unit value inch cm mm or sun do not ever turn the handwheel backwards If the exact unit value is missed do not turn the handwheel backwards Simply continue forward until the next exact unit value is reached This will prevent
28. ay YES or NO Should the UNITS key be able to select centimeters Should the UNITS key be able to select millimeters Should the UNITS key be able to select Japanese Sun 49 Are only whole numbers no fraction or decimal component to be used 46 Limit the key entry to whole numbers on the left side of the display YES or NO Is the power meter to be displayed during motor 47 Should the power meter Be displayed drive During motor drive YES or NO lt The power meter is an on screen display of how much voltage is being sent to the motor The computer will display a shorter or longer row of asterisks s depending on the amount of electricity being required to move the backgauge This can be a helpful tool for troubleshooting Is the length of the paper in front of the knife the 48 Display the cut A i portion that will be sheared off to be displayed length in front of the knife YES or NO lt Due to screen limitations 47 and 48 are mutually exclusive e g either the power meter or the cut length may be displayed but not both 50 49 Do roinantihe Should microcut automatically eject the stock before eae io push out it drives backwards so the operator does not have to Before any reverse reach under the knife and clamp to handle the stock Drive after a cut lt This is a great safety feature 50 The distance of the If auto eject was turned
29. ble sided tape to install each sensor securely to the machine according to the following criterion 1 Position Sense facilitates automatic calibration of the machine Move the backgauge to its rearmost position Mount the position sense so that it will be tripped by the gauge at least one inch 25 mm before the backgauge reaches this maximum mechanical rear position Do not mount the position sensor so far forward that the backgauge may move behind it and allow the sensor to become untripped as the gauge is moved to the extreme rear Do not mount the rear position sensor more than ten full encoder revolutions from the mechanical rear of the cutter lt Two inches from the maximum rear is usually the ideal distance A trip plate is supplied for the position sensor Use it if the cutter is heavily painted or if the surface to be sensed is not flat 2 Clamp up Sense limits drive if the clamp is not full up Mount this sensor so that it is tripped only when the clamp is in its full up position lt Horizontal mounting of the sensor barrel often prevents the complications that can arise when the sensor is mounted vertically hydraulic sag and soft return clamps can cause adjustment problems A trip plate is supplied for the clamp up sensor Use it if the cutter is heavily painted or if the surface to be sensed is not flat 14 3 Cut Sense senses knife cycling for PROGRAM and AUTOMATIC MODES X Mount this sensor to the side o
30. d Make sure that any tape used is secure X ADJUST THE MOTOR DRIVE BELT SO THAT IT IS LOOSE Some cutters have small bearings so too much tension on the drive belt can eventually cause mechanical problems there X USE AN A SECTIONAL BELT OR THINNER IF POSSIBLE Thick drive belts B size slow down positioning Ideally the belt should be a fractional horse power variety X DO NOT OVER TORQUE THE BACKGAUGE GIBBS and if there are nylon glider plugs in the backgauge make sure they are not tight against the table X USE ONE BELT PER PULLEY ONLY Multiple belts on any pulley will cause slower settling to the target position X DO NOT USE GREASE ON THE LEADSCREW MECHANISM Grease attracts abrasive dirt and acts as an inconsistent cushion against the backgauge preventing proper cutting precision Only use a light machine oil on the leadscrew Oil the leadscrew daily 11 Display Console The display console houses the computer that controls the motor interprets the information collected by the sensors and encoder and is the operator s interface with the system X X The display console should mount on the front of the cutter near the operator The display hangs on the aluminum bracket found in the top of the display console packing box Box 3 lt This bracket has two cuts along the bends to allow it to be bent if necessary lt The Panavise bracket top section of Box 2 is supplied to allow greater mounting flexibility The di
31. d be refitted Remove the Phillips screws from the sides of the display console and gently lift the cover off to gain better access to the plug in connectors lt If the cables are to run between the back side of the display console and the display mounting bracket make sure that the cables do not cross over each other to avoid space problems Shaft Encoder and Sensors Complete the connections to the display console for the shaft encoder and sensors Use the 6 conductor female female junction blocks and extension cables as required lt The four sensors are wired in such a way that they may be plugged into the four six pin RJ11 receptacles on the computer in any order The computer can tell which one is which by the way that they are wired at their connectors Isolation Transformer X Plug the 2 pin Phoenix type 12 V DC and the 5 pin Phoenix type 110 V AC power and motor cable connectors into the display console Wire the motor cable into the DC motor 1 The black and white wires from the motor cable connect to the Al and A2 wires from the motor lt The polarity of these wires does not matter Later in the SET UP ROUTINE the computer will adjust for this automatically Connect the green wire from the motor cable to the green wire from the motor with the 16 O wire nut supplied or to the case of the motor with the crimp connector supplied fa green wire exists on the motor it is case ground NOT a power conn
32. d for at least 2 second after slow speed drive before high speed is allowed SEMI AUTOMATIC DRIVE OPERATION may be achieved by either of these methods 1 To move the backgauge to a keyed in position enter the position to which you wish the backgauge to move with NUMBERS Then press MOVE 2 To move a predetermined distance press NO to clear the lower line of the display then press or before NUMBERS Then press MOVE 26 The PROGRAM MODE is used to program a series of stop points and commands into microcut to be executed in AUTOMATIC MODE lt These stop points and commands may be programmed in any order without regard for direction Press MANUAL Press PROGRAM Select a new job Select lowest number available or key in desired number Type in cut push load jog points or move to the desired position and cycle the knife to enter cut positions er aa ed Correcting and reviewing cut locations scrolls backward through the job enters position on lower line as a cut N clears lower line of the display O OPTIONS accesses programming alternatives MANUAL or AUTOMATIC exits PROGRAM MODE Knife Stroke enters current back gauge position as a cut 27 microcut contains programming options which can be accessed from PROGRAM MODE AUTOMATIC MODE or REVIEW MODE Press OPTIONS to access these options Then press OPTIONS to advance through the selections lt The actual options that microcut will present wi
33. d space to mount a second motor It may be necessary to remove the original motor and install the microcut motor in the original equipment space If this is the case completely insulate any bare wires label all wires and pack all mounting hardware with the original motor to facilitate reinstallation of the motor in the event microcut is moved to another machine at a later date The installer should document how the original motor should be refitted E Every installer will want to adapt this procedure It is merely intended to be a guide The procedures are listed in recommended order of execution Generally an installation will be much smoother if tasks are organized to allow use of the tools in a given category to completion before beginning to use the tools listed in the next category DETERMINE ALL microcut PART DRILLING LOCATIONS Mark all holes that will be drilled to complete mounting of ALL components including holes to secure ty strap brackets at the same time Slide T square with level Pencil DRILL ALL HOLES Protect the machine from drill shavings then drill all holes necessary to mount all components Use the pilot for all holes before increasing drill size to save time Be careful not to drill any hole too large as drill size is increased Paper and rags to cover machine surfaces Pilot 35 21 7 21 64 high speed drill bits Electric hand drill Extension cord TAP ALL HOLES Complete all threads for all of the c
34. drive ON Next screen To adjust the distance that microcut will travel to correct for backlash leadscrew play See page 49 step 35 To enable or disable backwards drive when the clamp is down See page 50 step 36 To see the next options screen press OPTIONS or 3 12 HW STATUS SCREEN 6 2 Settling 005 in Correcting ON Next screen O O To adjust the settling tolerance See page 50 step 37 To enable or disable auto correction See page 50 step 38 To see the next options screen press OPTIONS or 663 58 13 WSTATUS SCREEN7 1 True size ON Final digit ON Next screen 14 W UNITS STATUS 1 Inches ON Fractional ON Next screen 15 UNITS STATUS 1 Inches ON Fractional ON Next screen 16 W UNITS STATUS 1 gt Sun ON Left decimal ON Next screen To enable the true position or artificially perfect display See page 51 step 39 To display thousandths or only hundredths See page 51 step 40 To see the next options screen press OPTIONS or Le Ped To enable or disable inches See page 51 step 41 To enable or disable old fashioned cutter s fractions See page 52 step 42 To see the next options screen press OPTIONS or 3 To enable or disable centimeters See page 52 step 43 To enable or disable millimeters See page 52 step 44 To see the next options screen press OPTIONS or 3
35. e code This code is 3 1 7 5 YES Service code Press YES to return to MANUAL MODE or enter the service code to access the ADVANCED MANUAL MODE OPTIONS When the values to be modified in MANUAL MODE OPTIONS have been corrected simply continue pressing OPTIONS until the unit exits to MANUAL MODE or press 56 MANUAL PROGRAM or AUTOMATIC to enter those modes The following parameters are in the same order as found in the SET UP ROUTINE They may be accessed by pressing OPTIONS to change screens and then selecting the value to be altered See the SET UP ROUTINE for details regarding each individual step STATUS SCREEN3 1 To adjust the fast backgauge speed Fast 5 in sec See page 47 step 30 Slow 1 0 in sec Next screen To adjust the slow backgauge speed See page 47 step 31 To see the next options screen press OPTIONS or 663 3 57 OR 10 WSTATUS SCREEN 4 1 Manualaccel 10 Auto accel 40 Next screen To adjust rate of acceleration in MANUAL MODE See page 48 step 32 To adjust rate of acceleration in AUTOMATIC MODE See page 48 step 33 lt To adjust the rate of deceleration in AUTOMATIC MODE first press 2 to enter the automatic acceleration change screen and then press YES See page 50 step 34 To see the next options screen press OPTIONS or 3 OR 11 STATUS SCREEN 5 1 0 150 in Backlash Clamp
36. e display lt Any 12 V DC supply capable ofat least 1200 mA can be used to supply the computer for desktop demonstration purposes with microcut in DEMONSTRATION MODE Follow the first few steps of the SET UP ROUTINE to access DEMONSTRATION MODE lt A protection diode on the PC board prevents damage in the event that 12V DC is applied in reverse polarity but the connection must be of proper polarity before microcut will turn on X Ifa 110V AC source other than the transformer must be used it is imperative that this NOT be from a single leg of a WYE STAR or 4 WIRE transformer lt This type of power can cause frequency fluctuations X No type of surge protector or uninterruptable power supply may be used lt This type of device can represent an inductive or capacitive load on the line resulting in frequency fluctuations Inverter oscillator type units are even worse X The circuit breaker must be a 10A slow blow matching appropriate overload curves X The transformer supplied eliminates all possibilities of problems when wired correctly across TWO phases of the AC power to the machine If the transformer is not used all warranties expressed or implied will be void Cleaning Up X Use the spiral wrap supplied to enclose the cables exiting the display console X Use the ty straps and ty strap mounting bases to secure all cables appropriately lt Make sure that none of the cables can be damaged by moving parts of the machine
37. e equal then microcut is calibrated ii Ifthe first and or last strip is odd but all the rest are equal then perform the backgauge calibration in the MANUAL MODE OPTIONS iii If different pieces have different inaccuracies the reference positions programmed in the SET UP ROUTINE may not be accurate so perform the complete SET UP ROUTINE 65 f g Be certain that neither the shaft encoder sprocket or the leadscrew sprocket is loose Check for alignment Mark the sprockets and chain at 12 00 when the backgauge is at a mechanical reference point i e 8 500 or 35 or 110 cm then run the backgauge back and forth Check to see if the markings are still at 12 00 when the backgauge is at the same reference point 15 If the unit does not make excessive noise when driving the backgauge go to step 16 If it does then a b c d e f g h i j k Be certain that the motor turns at least 3 and not more than 6 revolutions for one inch 25 mm of backgauge movement Noise during acceleration Decrease the acceleration percentage in the MANUAL MODE OPTIONS Noise during deceleration Decrease the deceleration percentage in the MANUAL MODE OPTIONS Be certain that the motor mounting plate is secured directly to cutter not extended with threaded rod with at least three bolts Be certain that backgauge moves freely with handwheel no binding Be certain that the backgauge brake is fully released at all times If vibrat
38. ection Measure the 3 phase AC voltage into the machine s power panel Insure that the power in the main power panel is OFF Plug the power input cable into the appropriate voltage range jack on the side of the transformer lt Early versions of the microcut transformer model numbers lower than XL 1036 did not have plug in type connectors On these transformers change the jumpers to select the voltage range Wire the AC input primary side of the transformer to two legs of 3 phase power lt The green wire is for earth ground The other two wires are the AC power connections lt USE TWO PHASES OF THE THREE PHASE POWER DO NOT USE ONE HOT PHASE AND THE NEUTRAL LINE lt A single hot phase s frequency can be unstable but the frequency between two hot phases is constant An unstable frequency can cause poor motor drive performance settling problems and premature motor and mechanical wear A If the AC input is connected to the switched power on the cutter microcut will switch on and off with the machine Ifa separate ON OFF switch in desired this should be placed in series with the 12 V DC cable the 2 pin connector discussed above Power Connector Pin Outs 2 pin Phoenix type connector wiring right side of display under the number keys 17 5 pin Phoenix type connector wiring left side of display under the MOVE key 110 neutral case ground lt Pin 1 is the pin closest to the numeric keypad side of th
39. ed when the computer has stopped at a programmed cut 47 position within the programmed settling tolerance lt A NO here will cause the computer to display the backgauge position as perfect when it has settled on a mark in AUTOMATIC MODE as long as it is within the tolerance programmed in step 37 40 11 753 or 11 75 Do you want to see The final digit YES or NO 41 Do you want the UNITS key to select The inch display YES or NO 42 Do you want the UNITS key to select the fractional display YES or NO Select the number of digits to be displayed to the right of the decimal point lt Choose YES if microcut is to display thousandths 3 digits after the decimal point or NO if only hundredths are desired 2 digits after the decimal point Should the UNITS key be able to select inches Should the UNITS key be able to select old fashioned cutter s fractions 48 e 42 7 16 0 64 004 as opposed to 42 441 in lt microcut will still allow fractions to be input from the keyboard even if this question is answered NO This question only enables or disables the old fashioned cutter s fractional display 43 Do you want the UNITS key to select the centimeter display YES or NO 44 Do you want the UNITS key to select the millimeter display YES or NO 45 Do you want the UNITS key to select the SUN displ
40. essYES Enter first cut position Enter number of labels Enter label size Enter trim size If the backtrim is known and to be executed every time press YES I Stock size Trim to 30 Label size Trim The PROGRAM key allows an existing job to be called from memory The old job may be used modified or reviewed using the options in the REVIEW MODE 1 Beginning in MANUAL MODE press the PROGRAM key to enter REVIEW MODE 2 Select Review job s 3 Select the preferred job search method lt Press 1 to scroll through all jobs in memory in the order that they were programmed or press 2 to directly key in the number of the desired job 4 The job is now called from memory and is displayed on the screen lt Pressing AUTOMATIC will activate the job lt Pressing YES will advance the display to the next cut Pressing LAST will regress the display to the previous cut The entire job may be reviewed in this fashion if desired S Changes may be made to a program while in REVIEW MODE When the position to be modified is on the screen press OPTIONS lt See PROGRAM MODE OPTIONS for details 31 X The SET UP ROUTINE must be completed before proper operation can begin in any of the following cases 17 The computer is first installed on a machine 18 When an electrical event affects the calibration of the programmer 19 When the computer is removed from the machine and
41. f the opening in front of the knife bar so that it is tripped near the bottom of the knife stroke X This sensor must be tripped for at least 1 4 second during knife cycle to register a cut X This sensor must only be tripped once per knife stroke lt Beware the double tripping effect that bolt holes and heads can cause 4 False Clamp Sense adjusts the minimum backgauge drive position X Mount this sensor so that it is tripped when the false paper clamp sole plate is resting in its holder lt If there is no false clamp holder use the multi angled brackets supplied to create one Proximity Sensor Function and Cabling Specifications RJ11 6 conductor connector wiring lt Pin 1 is defined as the wire that plugs in closest to the display side of the console The internal wires are color coded Ss 15 Be sure that the original equipment backgauge motor cannot drive the leadscrew Be certain that the original equipment backgauge brake will not energize during motor drive If a clutch needs to be locked on electrically or mechanically to allow the microcut motor to drive do this now lt If any of the preceding three articles apply completely insulate any bare wires label all wires and pack all original parts that were removed Then to facilitate reinstallation of the original drive system in the event microcut is moved to another machine at a later date the installer should document how the original motor shoul
42. f two thousand counts every time the encoder completes a revolution lt If this does not occur the encoder turns ratio is incorrect See Shaft Encoder under MECHANICAL INSTALLATION 4 Release MANUAL and complete the SET UP ROUTINE L 75 microcut contains a PROXIMITY SENSOR TEST ROUTINE to verify that the computer is receiving information from the proximity sensors lt This test is usually executed at the Are all guards in place step of the START UP ROUTINE 1 Enter the START UP ROUTINE and proceed to the step that asks if all guards are in place Are all guards in place 2 Instead of answering the question press then then OPTIONS X if covered POS _ The display will then show the status of all four sensor signals CUT _CLAMP X FPC X An X will appear if the computer is receiving a signal from the sensor indicating the presence of metal less than 2 mm from its sensing surface X A ___ will appear if the computer is not receiving a signal indicating the presence of metal less than 2 mm from its sensing surface Q This example indicates that the clamp sensor and false paper clamp sensor are tripped and that the position sensor and cut sensor are not tripped 4 Press LAST to return to Are all guards in place 76 We are here to provide the support you need every business day Please call 8 30 to 5 00 Pacific time any weekday excluding holidays We are eager to do all that
43. far back can the backgauge travel before running into the back of the machine This example will use 45 inches 115 cm 27 Enter the false clamp width False clamp width is Inches across lt How far forward can the backgauge travel before running into the false paper clamp lt The false paper clamp is a smooth metal plate that may be attached to the paper clamp when clamping delicate stock This example will use 3 inches 7 62 cm LOLO 28 Enter the minimum cut value Most forward cut is 3 000 inches long 42 lt How far forward can the backgauge travel before running into the clamp when the false paper clamp is removed lt The false paper clamp is a smooth metal plate that may be attached to the paper clamp when clamping delicate stock This example will use 1 inch 2 54 cm LLL OC 29 MACHINE SIZES If the programmed machine sizes are correct press 45 000 in Maximum YES Otherwise press NO and return to step 26 3 000 in Clamp to enter the correct values 1 000 in Minimum lt microcut will now flow into the ADVANCED MANUAL MODE OPTIONS Once the ADVANCED MANUAL MODE OPTIONS information has been programmed the unit will be in MANUAL MODE and ready for use lt Any of the questions asked after this point may be modified later in MANUAL MODE OPTIONS without repeating the entire SET UP ROUTINE lt Note that ADVANCED MANUAL MODE OPTIONS follows on the next few pages
44. for almost any requirement Every display console is identical regardless of machine type A brief SET UP ROUTINE is resident in the computer to allow simple adaptation to any machine This routine must be completed on every installation in order for microcut to know the machine it is installed on and to operate safely and correctly Instructions for this routine are found in the OPERATION section of this manual The most significant differences in packing for various microcuts are the encoder sprocket set see SHAFT ENCODER cogged pulley for flat belt drive applications such as that found on many Schneider cutters and motor size If the machine leadscrew diameter is known at the time of shipment the leadscrew sprocket will be bored to the proper dimension Otherwise it may be necessary to have the sprocket bored to size Check the sprocket before beginning the installation If it must be bored take care of this NOW to avoid unnecessary delays later Have the sprocket cut in half to allow easier installation Position sense O E Motor microcut Motor Transformer Clamp False clamp KI Cut sense KA Display B Encoder Diagram 1 Top View lt Part locations are for reference purposes only Every installation will be unique Mount components for function and form not necessarily to mimic this diagram lt On some paper cutters it is not always possible to fin
45. hank you for purchasing microcut As part of a user base that numbers in the thousands worldwide you will soon begin enjoying the benefits of microcut and experience first hand why we are the leader in the field of cutter automation We would ask before installing microcut that you review the following points with your Authorized Dealer In doing so you will insure that microcut is a safe and productive addition to your operation for many years to come The microcut automatic backgauge control system is intended to increase both the quality and quantity of production possible on a machine while reducing the demands placed on the operator X Several methods of programming cutting sequences are available Each program is assigned a job number so that it can be recalled easily whenever required Automatic operation may then commence Memory is automatically divided for the number of cuts on each specific job so there are no memory allocation demands placed on the operator microcut is a computer controlled motor drive positioning system There are built in power limiting factors so that mechanical damage is not likely to occur in the event that proper lubrication schedules are missed but this is NOT a substitute for proper maintenance microcut is not intended to correctly drive a machine which is bound or damaged The handwheel must turn easily with one hand Iftwo hands are required to turn the handwheel then the leadscrew gibbs bear
46. heck to be certain that the encoder accumulator value on the screen changes during the motorized motion If not then i Be certain that the encoder is connected to the leadscrew ii Check the connections to the encoder 1 Replace the Female Female RJ45 telephone style coupler near the encoder 2 Replace the encoder cable 3 Replace the encoder 4 Replace the LS7083 or the display console If the backgauge stops when the position sensor is tripped go to step 8 If not then a b c If the light on the rear position sensor operates when it senses metal go to step 7 b If not then i Check the connections to the sensor ii Replace the sensor If the light on the position sensor operates when it senses metal i Adjust the sensor so that it is less than 2 mm from the metal it needs to sense ii Be certain that the sensor is positioned to trip when the backgauge is at least one inch 25 mm before but not more than 10 encoder revolutions from the maximum rear Perform the ENCODER TEST ROUTINE to verify that the computer is receiving encoder information 63 d Go to the PROXIMITY SENSOR TEST to see if the computer is getting information from the sensors If it is not remove the other three sensors CUS CUT FPC until the POS position sensor indication operates correctly Replace sensors as needed 8 Ifthe system does not ask for a new calibration value at this point go to step 9 If it does then a
47. ings and backgauge should be closely inspected and adjustments and repairs made BEFORE installing or operating microcut The addition of microcut will enhance the operation of your cutter Due to the extra productivity maintenance may be required more frequently This is the responsibility of the owner and not of the manufacturer or distributor of microcut microcut is intended for operation of the backgauge only Any alterations to any part s of the machine are the sole responsibility of the owner SOME SAFETY CONSIDERATIONS 1 microcut includes its own DC drive motor IT IS CRITICAL THAT MOTORS PULLEYS AND OTHER MOVING PARTS BE PROPERLY GUARDED The addition of the microcut motor may require the modification of an existing guard or its replacement UNDER NO CIRCUMSTANCES SHOULD microcut BE USED WITH AN UNGUARDED MOTOR PULLEY Affix the enclosed warning label to the cutter under the guard to discourage improper operation if the guard is ever removed 2 microcut SHOULD NEVER BE INSTALLED ON A CUTTER THAT DOES NOT MEET EXISTING SAFETY STANDARDS These standards include but are not limited to two hand start and hold for knife activation and a latching device for the knife when at the top of its cycle If you have any questions seek expert opinion before installing microcut 3 microcut will increase production It may be necessary to alter waste disposal methods so that material will not build up and impair the operator s mobility
48. ion occurs at high speed be certain that the backgauge carriage and leadscrew are secure Be certain that the motor belt is not too tight Be certain that the transformer is wired to two of the incoming power phases not to the neutral line Be certain that the correct motor is being used Attach the motor to the mounting plate with a rubber washer between bolt head and motor base and between motor base and mounting plate 8 washers total 16 If the CUT READY indication does not flicker on and off go to step 17 If it does then a b Increase the settling tolerance in the MANUAL MODE OPTIONS If you move the handwheel and then release it it should not move backwards If it does then there is mechanical elasticity causing a problem called flexback Try tightening or loosening the motor belt Check for mechanical binds over tightened nylon plugs in the backgauge misadjusted gibbs or compensating nuts etc 66 microcut retrofit spacer systems display prompts to tell the operator of existing or pending error conditions The following list is a synopsis of the codes from these units START UP PROMPTS FAILURE RECOGNIZED Main CPU has failed to power on properly restart microcut FAILURE RECOGNIZED Job memory is losing data service needed before operating Encoder direction data has been lost A key appears to be pushed Check keys Refer to KEY TEST in OWNER S MANUAL Calibration lost Turn power off
49. ll depend upon the mode from which the options were accessed and whether a value is displayed on the lower line or not For instance if no numbers are on the lower line push load jogging point change cut insert cut or delete cut would not have any meaning and therefore would not be offered X CHANGE CUT Adjusts the stop location X AIR CONTROL Forces the air control off for the entire positioning cut cycle lt Only if this optional circuit was installed with this particular microcut X LAY COMPENSATE Adjusts all forward moving stop values up to the END JOB lt A very useful tool if the position of the image on the paper should happen to move X STOCK PUSH Moves the gauge to the programmed position then immediately moves to the next position lt This can be used to bring the stock to the operator thereby eliminating the necessity for an operator to reach under the knife and clamp to handle the stock X JOG LOAD Positions the gauge without incrementing the cut number count lt This is useful to provide a point where the pile can be jogged before the computer positions the back gauge at a cutting location X INSERT Adds a cut in front of the one shown on the display X DELETE Removes the cut that is shown on the display X LABELS Programs stop values for a step and repeat sequence lt Tell microcut how long the stock is how many pieces labels are to be rendered and the trim between them and the com
50. microcut Please Note The following product manual is presented in its original form The contact information included may be outdated Please use the current contact information below Thank you C amp P Microsystems 1260 Holm Road Suite C Petaluma CA 94954 Main Number 1 707 776 4500 Fax Number 1 707 776 4555 www cp microsystems com CaP microsystems microcut owner s manual Revision 498 GMS GRAPHIC MACHINERY amp SYSTEMS A DIVISION OF GOLDEN GATE MICROSYSTEMS INC 30 Golden Gate Drive San Rafael Ca 94901 Tel 415 457 7500 Fax 415 457 1694 e mail graphicmachinery com http www graphicmachinery com Table of Contents Introduction Installation Manual Installation Installation Diagram Recommended Installation Guide and Tool List Installation Notes Mechanical Installation Proximity Sensor Function and Cabling Specifications Wiring and Power Power Connector Pin Outs Wiring Diagram Optional Control Lines Operation Manual Operation Start up Routine Manual Drive Operation Programming a Job Programming Options Label Mode Retrieving a Job from Memory Set up Routine Sample Set up Routine Manual Mode Options Manual Mode Options Details Advanced Manual Mode Options Service Manual Service and Troubleshooting Prompt Error Message List Testing the Keyboard Testing the Encoder Testing the Proximity Sensors Factory Phone Support and Returns for Service Dear Valued Customer T
51. omponents 6 32 10 32 1 4 20 3 8 16 taps Tap handles ratchet type are convenient Tapping fluid CLEAN ALL METAL FILINGS OFF OF THE MACHINE Clean the machine to prevent future damage Brush Rags BOLT AND SECURE ALL microcut PARTS TO THE MACHINE 7 16 2 9 16 wrenches and sockets Crescent wrench Hacksaw to saw off excess threaded rod ROUT THE CABLES Complete wiring of all components Trim off excess length on all ty straps 7 8 inch hole punch for transformer AC input wiring Common and Phillips screw drivers Side flush cut pliers TAP SIZE 10 32 1 4 20 5 16 18 3 8 16 lt Most charts recommend 5 16 bit for 3 8 16 tap but 21 64 makes tapping much easier 10 microcut is a retrofit system for many different types of machines All installations will vary This text is designed to give a conceptual approach toward the installation Use this manual to learn what each component must do then mount the component in the fashion best suited to fulfill its purpose X The boxes are packed to facilitate the installation The installation will be easier if the parts are not mixed up Box 1 contains the backgauge drive motor Box 2 contains the transformer encoder proximity sensors and various brackets Box 3 contains the encoder sprockets the Owner s Manual the display console mounting bracket and the display console X USE THE CLEANING PADS to thoroughly clean any surfaces before double sided tape is applie
52. ond and allow language selection go to step 4 If not then a Remove the cover and check to be certain the keyboard ribbon cable is properly attached b Perform the keyboard test routine 4 Ifthe unit asks Are all guards in place Is daily lubrication complete and Is everyone clear of the machine and then displays PRESS AUTOMATIC TO START then go to step 5 If not then a If there is a memory error check for a loose Dallas memory chip Replace if necessary b If there is a stuck key start over again with the KEY TEST ROUTINE c Ifthere isan AC POWER error then i Check the connections to the power supply ii Check the circuit breaker on the power supply iii Replace H11L1 s or replace the display console d Ifthe computer does not respond to the language selection then replace the drive side 80535 microcontroller 62 5 Ifthe backgauge moves either direction even a little bit when lt AUTOMATIC gt is pressed then go to the next section If not then 6 7 a Check to be certain that i The backgauge is not bound ii The motor belt is connected to the leadscrew iii There is no connection problem between the display console and the motor iv With power off the 5 pin Phoenix terminal to the motor measures about 2 ohms If the backgauge goes backward then go to step 7 If not then a b If the backgauge goes forward perform the SET UP ROUTINE If the screen says No Motion Seen after some motion then c
53. or display an error message If a Cut Sensor is installed press YES 37 15 16 17 18 KNIFE SWITCH CHECK Is the knife in the Full up position YES or NO Is the backgauge at Least 10 inches from the max rear YES or NO MOTOR DIRECTION TEST Use the UP ARROW key Does the gauge move back YES or NO NCAUTION Drive is operator controlled Avoid collisions If the Cut Sensor is properly installed and the knife is in the up position press YES lt The computer will then verify the Cut Sensor signal and either continue the SET UP ROUTINE or display an error message Be certain that the backgauge is at least 10 inches 25cm from the rear of the cutter then press YES lt The backgauge must be at least 10 inches from the rear of the table to avoid damage during this procedure Press the UP ARROW key for a few seconds and observe the movement of the backgauge lt Encoder function may be verified by executing the ENCODER TEST ROUTINE at this point lt BE CAREFUL The backgauge is under the control of the operator and damage to the machine and human injury are depending on operator caution 38 19 MOTOR DIRECTION TEST If the backgauge moved toward the rear of the cutter Use the UP ARROW press YES If it moved toward the front press Does the gauge move back NO YES or NO lt The computer will automatically orient the motor polarity as necess
54. pleted Is daily lubrication completed 24 Look around the machine to make sure that no one is Is everyone clear of the near any of the moving parts and that nothing has been machine left on the table surface which could be damaged Press YES to continue 6 Press AUTOMATIC and microcut will test the Press the AUTOMATIC motor drive briefly moving back and forth and then it key to calibrate will slowly and automatically move the backgauge to the rear of the cutter to calibrate It will display the correct position and MANUAL MODE when ready AUTOMATIC 7 IN CASE OF EMERGENCY lt Do not press a key unless an immediate Press any key for emergency stop is needed Immediate stop lt If the backgauge is already at the rear of the machine it will begin by driving the backgauge forward first 8 45 000 inches microcut is ready for normal operation MANUAL MODE Job 1 Cut 9 33 575 25 X Press MANUAL to enter MANUAL MODE SLOW FORWARD DRIVE may be achieved by any of the three following methods 1 Tap UP ARROW and then hold DOWN ARROW 2 Press DOWN ARROW release it for less than 2 second then press and hold DOWN ARROW again 3 Lower the clamp briefly while pressing DOWN ARROW SLOW REVERSE DRIVE Press UP ARROW then release it for less than 2 second then press and hold UP ARROW again FAST DRIVE Press and hold UP or DOWN arrow as desired lt The drive keys must be release
55. puter will calculate the positions automatically X SHEET DIVIDE Divides a sheet into equal sizes 28 X CHANGE JOB NUMBER Modifies the currently assigned job number lt Press OPTIONS from this screen to protect the program from unauthorized modifications lt Protection will be enabled when MANUAL MODE is commenced The management code must then be entered before the PROGRAM OPTIONS ROUTINE can be accessed That code is 2 9 8 4 YES X DELETE JOB Removes the job from memory Programming Options These are the only options available if a value IS NOT displayed on bottom line of screen PROGRAM MODE REVIEW MODE AUTOMATIC MODE label mode label mode label mode sheet divide change job number change job number delete job delete job These are additional options available if a value IS displayed on bottom line of screen PROGRAM MODE REVIEW MODE AUTOMATIC MODE air control air control stock push stock push stock push load jogging point load jogging point load jogging point delete cut delete cut delete cut 29 Microcut can calculate cutting positions automatically for a step and repeat sequence when the length of the stock how many pieces labels are to be rendered and the trim between them is known 7 8 9 10 11 12 13 14 15 16 Press MANUAL Press PROGRAM Select a new job Select lowest number available or key in desired number Press OPTIONS until Label mode appears then pr
56. r However if the final result calculated is larger than the maximum rear value this prompt will show Ifa cut is made in the PROGRAM MODE that is behind the maximum rear value as entered in the SET UP ROUTINE this error will appear 69 Cannot be zero Number too small Number too big CLAMP DOWN The fraction when using the calculator keys cannot have zero in the denominator The result of a subtraction is less than zero or the target position is less than the physical table limit see TOO FAR FORWARD The sum of numbers when using the calculator keys is larger than the maximum allowed value maximum rear value usually or twice the maximum rear value in LABEL or SHEET DIVIDE ROUTINE At least one of microcut s internal data backup registers does not agree with the others regarding the position to which microcut should drive lt microcut performs its operations in several areas at the same time in order to compare results If electrical disturbances occur which prevent the results from being equal microcut halts operation with this error prompt This safety gives assurance that microcut will not make errors in positioning If this message occurs often check the microcut power supply line very carefully The clamp sensing switch may not be tripped properly Be certain that the clamp is in the full up position and that the sensor is less than 2 mm from the metal it must sense CUT STROKE EARLY
57. rate is PERCENTAGE percent of maximum rate lt How fast does the computer have to accelerate to reach the programmed maximum speed in AUTOMATIC MODE lt Any percentage is legal but 35 65 is the common range and assures smoother starts to extend machine life This example will use 50 34 Deceleraton of A eS tie MODE DECELERATION Too high a value may Cause vibration when Slowing down 45 lt How hard does the computer have to step on the brakes when trying to stop at a cut location in AUTOMATIC MODE lt Any percentage is legal but 35 65 is the common range and assures smoother stops lt Too high a value may cause vibration when slowing down is not an error message or an indication that the value that has been entered is invalid It is merely a helpful on screen tip This example will use 50 35 BACKLASH ADJUSTMENT Enter BACKLASH CORRECTION value Gauge will move 000 in behind target to lt How far does the computer have to move the zero backlash backgauge behind the mark before coming forward to stop on a mark in AUTOMATIC MODE This is performed to remove the play or slop in the leadscrew from the measurement lt Any value is legal but 100 250 inches 25 mm 65 mm is the common range and provides sufficient correction for most cutters The more worn the leadscrew is the greater this number must be This example will use 150 inches 0 381
58. rrections must be made in order to go further The cut switch has a wiring error The position sense has a wiring error The shaft encoder is turning too quickly change gearing for 2 to 4 turns per inch The shaft encoder is turning too slowly change gearing for 2 to 4 turns per inch Mechanical changes are required for the installation to be to specification Encoder turns ratio is too great for mm calibration on this machine use cm The NO key has been pressed in response to one of microcut s switch checking questions in the SET UP ROUTINE questions Adjustments will need to be made to correct the incorrect condition before the SET UP ROUTINE can be continued Either microcut senses that the clamp is down when it is should be up or the clamp switch did not operate during a knife cycle Check to be certain that the pile height of the stock being cut allows the clamp to travel down far enough to untrip the clamp sensor Adjust if necessary An error has occurred which requires attention before continuing Read the other prompts which alternate with this one to determine what needs to be corrected Either the CUT sensor is broken unplugged or the knife is down during the SET UP ROUTINE or another sensor is shorting out the CUT sense line Corrections will need to be made before continuing Either the rear position sensor is broken unplugged or covered during the SET UP ROUTINE or another sensor i
59. s manual for job memory assistance YES or NO The job in use has been code protected to prevent Key access code 000 anyone from changing or deleting it You must enter to enter the OPTIONS the appropriate code at this time to make changes routine Code Refer to PROGRAMMING OPTIONS in this manual for assistance microcut only allows small alterations in calibration If the change is too great it assumes an error has been made It may be necessary to perform the SET UP ROUTINE or the rear position sensor may need to be moved forward Calibration error is too great OPTIONS ROUTINE MESSAGES PI The proper service code is required to go further This ease enter your code is 3 1 7 5 YES Service code INFORMATION ERROR AND WARNING MESSAGES microcut has been knocked out of position while in AUTOMATIC MODE The gauge HAS BEEN in position and microcut will still recognize the cut sensor if the knife is operated POSITION OUT The position that was requested is beyond the physical limits Too FAR forward of tetanie The position that was requested is beyond the physical limits of the table Too FAR back lt microcut limits the prompt display to realistic values as the number keys are pressed ifthe resulting number is larger than the maximum rear it blanks the leading digit However in the CALCULATOR LABEL and SHEET DIVIDE ROUTINES microcut temporarily allows values to twice the maximum rea
60. s shorting out the position sense line Corrections will need to be made before continuing microcut has determined that the encoder gearing is incorrect It will be necessary to change the sprockets in order to correct this microcut has determined that the encoder gearing is incorrect It will be necessary to change the sprockets in order to correct this This will appear after another clarifying prompt if certain requirements have not been met There are too many turns of the encoder for microcut 72 to calibrate this machine in mm during the SET UP ROUTINE Use cm instead 73 microcut contains a full KEYBOARD TEST ROUTINE available immediately after power on BEFORE the language selection is made This should be used if any key does not operate or is stuck Turn the power off Wait a few seconds Turn the power on The display will ask for a language selection Use NO OPTIONS LAST or ARROWS to position the pointer to the language you would like to use but DO NOT USE 1 2 or YES TO ACTUALLY MAKE THE LANGUAGE SELECTION Press to enter the KEYBOARD TEST ROUTINE The upper part of the display will now read KEYBOARD TEST MODE Whenever a key is activated the value of that key will show in the third line of the display until the key is released If a key is stuck the display will show the value of the stuck key To exit the KEYBOARD TEST ROUTINE press or turn the power off Note microcut will default to
61. splay may alternatively be affixed directly to the cutter using only the aluminum bracket Drill and tap the appropriate holes and mount the display so that it is secure Shaft Encoder The shaft encoder sends pulses to the computer to indicate backgauge position movement speed and direction X Use the shaft encoder mounting bracket supplied to mount the shaft encoder near the leadscrew Mount a sprocket to the encoder shaft that will allow it to turn at least two but not more than four turns for one inch 25 mm of backgauge movement lt This may be the most common error that novice installers commit Having the incorrect encoder turns ratio can result in on screen error messages inaccuracy positioning difficulties and mathematical errors in the current position readout Clamp the sprocket to the leadscrew with the supplied hose clamp so that it aligns with the encoder sprocket lt Depending upon the machine the sprocket may need to be bored or cut in half lt It is easier to assure that the sprocket faces align if the chain is wrapped around the sprocket while the hose clamp is tightened Install the chain on the sprockets making sure both sprocket faces are aligned Adjust the chain tension so that it is snug but not too tight 12 DC Drive Motor The motor turns the leadscrew according to the drive signals supplied by the computer X a The motor must turn at least three but not more than six times
62. te main computer It will be necessary to power down on AC power Check and restart the system to insure proper cutting accuracy Supply line status ERROR Power These three screens indicate that microcut has diagnosed an error in counting Check or replace the connection between the display console and the shaft encoder Turn the power off and restart microcut Power off restart Refer to SERVICE AND TROUBLESHOOTIING Zero set error Too many counts seen Zero set missed Zero set occurred too early CALIBRATION amp TEST ROUTINE PROMPTS Interruption Data Has been lost Turn microcut has diagnosed an error in counting Check the connection between the display console and the shaft encoder Turn the power off and restart microcut Refer to other parts of this manual for assistance microcut has sensed a failure in the job memory and Memory failure will not allow operation to continue Turn the power Turn power off off It is advisable to enter the SET UP ROUTINE and test the memory lt If the error is fairly high in the address range it may be possible to erase some of the lower jobs and continue on microcut may skip over the bad location after power is turned off but memory errors may occur if jobs are altered in the future Schedule service 71 on the memory chip as soon as possible Make adjustments To continue The clamp switch has a wiring error 1 TURN POWER OFF Co
63. the KEYBOARD TEST ROUTINE when power is turned on if is stuck in 74 microcut contains an ENCODER TEST ROUTINE to verify that the computer is receiving positioning information from the encoder lt This test may only be executed from within the SET UP ROUTINE at the motor direction test Step MOTOR DIRECTION TESI 1 Enter the SET UP ROUTINE and proceed to the Use the UP ARROW key step that asks the operator to use the arrow keys to test Does the gauge move back the motor direction YES or NO 2 Instead of pressing an arrow key press and hold MANUAL MANUAL 3 The display will place a six digit number on the top 200000 line that is the current encoder accumulator count Turn handwheel 2000 position Display counts per revolution lt This number does not correspond to inches cm mm or Japanese sun it is just quadrature information from the encoder X Turn the handwheel backward and forward and observe the count display lt The number should count up and down intelligently when the handwheel is rotated 1 2 3 4 5 6 no breaks lock ups or jumping around lt If this does not occur the encoder has failed the connection to the encoder has failed or the computer is not able to interpret the encoder information Check the connections or try unplugging and replugging the connections Then try replacing the female female RJ45 connector cable or encoder X The display should show a change o
64. the programmed settling tolerance is not too small This may be reprogrammed in the MANUAL MODE OPTIONS if necessary Be certain that the motor belt tension is correct Typically tight belts will cause settling problems Check for a bind in the backgauge Check for leadscrew flex back Perform the SET UP ROUTINE to get microcut learning the dynamic inertial and frictional settling parameters eagerly again Be certain that the correct motor is being used 11 If the unit moves in AUTOMATIC mode after each cut go to step 12 If not then a Go to the PROXIMITY SENSOR TEST and verify that the computer sees the CUT sensor trip during the knife stroke If it does not i Check the connections to the sensor ii Adjust the sensor so that it is less than 2 mm from the metal it needs to sense 64 iii Be certain that the sensor is positioned to trip when the knife is in the down position iv Be certain that the sensor is not positioned to where it may double trip over a bolt hole or other odd feature v Replace the sensor vi Remove the other three sensors CUS FPC POS until the CUT cut sensor indication operates correctly in the PROXIMITY SENSOR TEST routine Replace sensors as needed 12 If the unit does not suffer count errors go to step 13 If it does then a Verify that the encoder turns at least 2 but not more than 4 turns for one inch of backgauge movement If it does not then change the sprockets and perform the S
65. ue This position is 000 inches EXACTLY lt lt When turning the handwheel to move the backgauge to an exact unit value inch cm mm or sun do not ever turn the handwheel backwards If the exact unit value is missed do not turn the handwheel backwards Simply continue forward until the next exact unit value is reached This will prevent backlash from entering the measurement This example will use 5 inches 13 cm Final absolute calibration can be fine tuned later See CALIBRATE GAUGE ROUTINE in MANUAL MODE options It is more important that the displacement between the rear reference and the front reference be precise than the absolute accuracy of the positions These calibration points allow microcut to calculate the leadscrew pitch If the displacement 41 is not accurate microcut will not be able to calculate the leadscrew pitch properly If microcut cannot do this an accumulating position error will occur as the backgauge is moved up or down the cutter If possible reference the positions to the handwheel or leadscrew pulley this allows more accurate readings in the same way that a dial gauge assists a machinist reading a pair of calipers lt Ifa tape band or periscope must be used keep in mind that backlash tape band stretch and non level or warped tables can have a significant effect on the readings taken 26 Furthest position is Enter the maximum rear value Inches back lt How

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