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included may be outdated.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&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
 ®
microcut
owner's manual Revision 498

GRAPHIC MACHINERY & 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

Table of Contents 1
Introduction 3
Installation Manual 7
Installation 9
Installation Diagram 10
Recommended Installation Guide and Tool List 11
Installation Notes 12
Mechanical Installation 13
Proximity Sensor Function and Cabling Specifications 16
Wiring and Power 17
Power Connector Pin Outs 18
Wiring Diagram 20
Optional Control Lines 21
Operation Manual 23
Operation 25
Start up Routine 26
Manual Drive Operation 28
Programming a Job 29
Programming Options 30
Label Mode 32
Retrieving a Job from Memory 33
Set up Routine 35
Sample Set up Routine 37
Manual Mode Options 55
Manual Mode Options Details 57
Advanced Manual Mode Options 61
Service Manual 65
Service and Troubleshooting 66
Prompt Error Message List 71
Testing the Keyboard 78
Testing the Encoder 79
Testing the Proximity Sensors 80
Factory Phone Support and Returns for Service 81

1
2
 INTRODUCTION

Dear Valued Customer,

Thank 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.

Χ 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.

Χ 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.

Χ microcut is not intended to correctly drive a machine which is bound or damaged.

The handwheel must turn easily with one hand. If two hands are required to turn the
handwheel, then the leadscrew, gibbs, bearings and backgauge should be closely
inspected and adjustments and repairs made BEFORE installing or operating
microcut.

Χ 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.

Χ 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.

3
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.

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.

4
 Everything safely possible has been done to ease the installation of microcut. With
proper care, it has 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 & 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 & SYSTEMS.

microcut7 is a registered trade mark of golden gate microsystems, inc.

Serial Number
Date
Cutter Brand
Dealer
Installed by

5
 ®
microcut
installation manual

6
7
 INSTALLATION
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 KNIFE 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. All 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 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.

8
 INSTALLATION DIAGRAM

Diagram 1 - Top View

< Part locations are for reference purposes only. Every installation will be unique. Mount
components for function and form, not necessarily to mimic this diagram.

< On some paper cutters, it is not always possible to find 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.

9
 RECOMMENDED INSTALLATION
GUIDE AND TOOL LIST
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 components.
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

DRILL BIT #35 #21 #7 1/4" 21/64"

TAP SIZE 6-32 10-32 1/4-20 5/16-18 3/8-16

< Most charts recommend 5/16" bit for 3/8-16 tap, but 21/64" makes tapping much easier.

10
 INSTALLATION NOTES
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.

Χ 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.

Χ USE THE CLEANING PADS to thoroughly clean any surfaces before double sided tape
is applied. Make sure that any tape used is secure.

Χ 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.

Χ 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.

Χ 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.

Χ USE ONE BELT PER PULLEY ONLY. Multiple belts on any pulley will cause slower
settling to the target position.

Χ 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
 MECHANICAL INSTALLATION
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.

Χ 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).
< This bracket has two cuts along the bends to allow it to be bent if necessary.
< The Panavise bracket (top section of Box 2) is supplied to allow greater
mounting flexibility. The display may alternatively be affixed directly to the
cutter using only the aluminum bracket.

Χ 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.

Χ Use the shaft encoder mounting bracket supplied to mount the shaft encoder near the
leadscrew.

Χ 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.
< 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.

Χ Clamp the sprocket to the leadscrew with the supplied hose clamp so that it aligns with
the encoder sprocket.
< Depending upon the machine, the sprocket may need to be bored, or cut in half.
< It is easier to assure that the sprocket faces align if the chain is wrapped around
the sprocket while the hose clamp is tightened.

Χ 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.

Χ The motor must turn at least three, but not more than six times for each inch (25 mm) of
backgauge movement.
< 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.

Χ If possible, it is convenient to mount the microcut motor so that it lines up with the
existing leadscrew drive pulley.
< 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.
Χ If the motor mounting method does not isolate the original drive system, other means
will be required.

Χ Keep the drive belt LOOSE to insure smoothest operation.

< Too much motor belt tension can cause settling problems.

Χ 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.

Χ Original motor will need to be removed.

< Make sure wires are labeled and taped.

Χ The brake will have to be disabled and the drive clutch enabled to allow proper
operation
< This can often be done by flipping the wires between the clutch and brake.
Χ The motor plate may need to be spaced down slightly to avoid conflict with the original
equipment backgauge drive control panel.

Χ 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.

< Make sure that all wires are properly insulated.

< 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.

Χ This insures reliable operation when microcut is wired directly to 3 phase power.

Χ 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).
< 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.
< Wiring is discussed in detail in the WIRING AND POWER section of this
manual.

Proximity Sensors

Proximity sensors monitor the status of the machine.

Χ Each sensor has a label indicating its purpose. Each sensor must be installed according
to its designation.

Χ An LED on each sensor indicates when it detects metal within 0.1 inches(2 mm) of the
face of the sensor barrel.

Χ Use any combination of brackets, hardware, and double sided tape to install each sensor
securely to the machine according to the following criterion:

1. Position Sense (facilitates automatic calibration of the machine)--

Χ Move the backgauge to its rearmost position.

Χ 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.

Χ 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.

Χ Do not mount the rear position sensor more than ten full encoder revolutions from the
mechanical rear of the cutter.
< Two inches from the maximum rear is usually the ideal distance.

Χ 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)--

Χ Mount this sensor so that it is tripped only when the clamp is in its full up position.

< 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.

Χ 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)

Χ Mount this sensor to the side of the opening in front of the knife bar so that it is tripped
near the bottom of the knife stroke.

Χ This sensor must be tripped for at least 1/4 second during knife cycle to register a cut.

Χ This sensor must only be tripped once per knife stroke.

< Beware the double-tripping effect that bolt holes and heads can cause.

4. False Clamp Sense (adjusts the minimum backgauge drive position)--

Χ Mount this sensor so that it is tripped when the false paper clamp (sole plate) is resting in
its holder.
< If there is no false clamp holder, use the multi-angled brackets supplied to create
one.

Proximity Sensor Function and Cabling Specifications

The sensors conduct to ground (LED is on) whenever . . .

POSITION SENSE the gauge is not near the rear of the machine
CLAMP UP SENSE the clamp is in the full up position
CUT SENSE the knife is at the top of its stroke
FALSE CLAMP SENSE the false clamp is in its holder

RJ11 6 conductor connector wiring

Pin 1 DC voltage to power the proximity sensors
Pin 2 ground
Pin 3 signal line for the position sense
Pin 4 signal line for the clamp up sense
Pin 5 signal line for the cut sense
Pin 6 signal line for the false clamp sense

< Pin 1 is defined as the wire that plugs in closest to the display side of the console.
The internal wires are color coded.

15
 WIRING AND POWER
Χ Be sure that the original equipment backgauge motor cannot drive the leadscrew.

Χ Be certain that the original equipment backgauge brake will not energize during motor
drive.

Χ If a clutch needs to be locked on (electrically or mechanically) to allow the microcut

motor to drive, do this now.

< 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 should be refitted.

Χ 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.

< 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

Χ Complete the connections to the display console for the shaft encoder and sensors.

Χ Use the 6 conductor female-female junction blocks and extension cables as required.

< 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

Χ 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.

Χ Wire the motor cable into the DC motor.

1. The black and white wires from the motor cable connect to the A1 and A2 wires
from the motor.
< The polarity of these wires does not matter. Later, in the SET UP
ROUTINE the computer will adjust for this automatically.

Χ Connect the green wire from the motor cable to the green wire from the motor with the
16
 wire nut supplied or to the case of the motor with the crimp connector supplied. If a
green wire exists on the motor, it is case ground, NOT a power connection.

Χ Measure the 3 phase AC voltage into the machine's power panel.

Χ Insure that the power in the main power panel is OFF.

Χ Plug the power input cable into the appropriate voltage range jack on the side of the
transformer.

< 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.

Χ Wire the AC input (primary side of the transformer) to two legs of 3 phase power.

< The green wire is for earth ground.

< The other two wires are the AC power connections.
< USE TWO PHASES OF THE THREE PHASE POWER. DO NOT USE
ONE HOT PHASE AND THE NEUTRAL LINE.
< 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.

If the AC input is connected to the switched power on the cutter, microcut will switch
on and off with the machine.

If a 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)
Pin 1 ground
Pin 2 12 V DC

17
 5 pin Phoenix type connector wiring
(left side of display, under the MOVE key)
Pin 1 110 hot
Pin 2 110 neutral (case ground)
Pin 3 earth
Pin 4 motor
Pin 5 motor
< Pin 1 is the pin closest to the numeric keypad side of the display,

< Any 12 V DC supply capable of at 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.)

< 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.

Χ If a 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.
< This type of power can cause frequency fluctuations.

Χ No type of surge protector or uninterruptable power supply may be used.

< 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.

Χ The circuit breaker must be a 10A slow blow, matching appropriate overload curves.

Χ 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

Χ Use the spiral wrap supplied to enclose the cables exiting the display console.

Χ Use the ty straps and ty strap mounting bases to secure all cables appropriately.

< Make sure that none of the cables can be damaged by moving parts of the
machine.

Χ Refit the display cover and tighten the Phillips screws on both sides.

18
 WIRING DIAGRAM

JUMPER CONFIGURATION FOR EARLY STYLE

TRANSFORMERS (model #=s lower than XL1036)

AC Input voltage Jumper terminals

180 V AC to 250 V AC 1 to 2 and 3 to 4

360V AC to 500 V AC 2 to 3

19
 OPTIONAL CONTROL LINES
microcut is equipped with control lines which can be used to activate relays that control the air
table and original equipment brake.

Χ These must have 12V DC coils requiring no more than 250 mA for operation.
< Check current requirements of the circuit being controlled to specify the contact
current rating.

Χ 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.

Χ 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
Pin 1 Air control return
Pin 2 Brake control return
Pin 3 Positive coil voltage
Pin 4 Ground reference for external power source
Pins 5, 6 & 7 Original equipment operations (AKO, AKE, CD)

< Pin 1 is the pin which is closest to the sensor cable inputs.
< On some units, the connector will only offer the first three connections.

AIR CONTROL (pin 1)--Provides a current path (ground) for the coil of a 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.

< 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.

Χ An optional relay board assembly is available from GMS, if the parts are not available
locally.

20
 ®
microcut
operation manual

21
22
 OPERATION
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 MANUAL MODE
33.575
Line 3 displays the current job and cut number.

Line 4 displays the current target position

33.575

< 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.)
< The jobs can be modified to correct for errors or make changes.
< 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
 START UP ROUTINE
1.
TURN ON POWER

2. Select the language desired and press "YES."

→ English
Espanol
Other OPTIONS . . . .

OR
1 YES

3. Make sure all mechanical guards are in place. Inspect

Are all guards in place? the machine to ensure proper and safe operation, then
press "YES."

YES

4. The leadscrew should be lubricated with light machine

oil, fluid levels should be checked, and routine
Is daily lubrication
cleaning should be performed on the machine at this
completed? time. Press "YES" when completed.

YES

24
5. 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.

YES

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 < Do not press a key unless an immediate,
Press any key for emergency stop is needed.
Immediate stop!!
< 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
 MANUAL DRIVE OPERATION

Χ 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.

< The drive keys must be released 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
 PROGRAMMING A JOB

The PROGRAM MODE is used to program a series of stop points and commands into microcut
to be executed in AUTOMATIC MODE.
< These stop points and commands may be programmed in any order, without regard for
direction.

2. Press MANUAL.
3. Press PROGRAM.
4. Select a new job.
5. Select lowest number available or key in desired number.
6. Type in cut, push, load/jog points or move to the desired position and cycle the knife to
enter cut positions.

Correcting and reviewing cut locations

LAST scrolls backward through the job
YES enters position on lower line as a cut
NO clears lower line of the display
OPTIONS accesses programming alternatives
MANUAL or AUTOMATIC exits PROGRAM MODE
Knife Stroke enters current back gauge position as
a cut

27
 PROGRAMMING OPTIONS

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.

< The actual options that microcut will present will 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.

Χ CHANGE CUT- Adjusts the stop location.

Χ AIR CONTROL- Forces the air control off for the entire positioning/cut cycle.
< Only if this optional circuit was installed with this particular microcut

Χ LAY COMPENSATE- Adjusts all forward moving stop values up to the END JOB.
< A very useful tool, if the position of the image on the paper should happen to
move.

Χ STOCK PUSH- Moves the gauge to the programmed position then immediately moves
to the next position.
< 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.

Χ JOG/LOAD- Positions the gauge without incrementing the cut number count.
< This is useful to provide a point where the pile can be jogged before the
computer positions the back gauge at a cutting location.

Χ INSERT- Adds a cut in front of the one shown on the display.

Χ DELETE- Removes the cut that is shown on the display.

Χ LABELS- Programs stop values for a step and repeat sequence.

< Tell microcut how long the stock is, how many pieces (labels) are to be rendered,
and the trim between them, and the computer will calculate the positions
automatically.

Χ SHEET DIVIDE- Divides a sheet into equal sizes.

28
Χ CHANGE JOB NUMBER- Modifies the currently assigned job number.

< Press OPTIONS from this screen to protect the program from unauthorized
modifications.
< 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.

Χ 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 sheet divide 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

change cut change cut change cut
air control air control
lay compensate
stock push stock push stock push
load/jogging point load/jogging point load/jogging point
insert cut insert cut insert cut
delete cut delete cut delete cut

29
 LABEL MODE

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. Press MANUAL.
8. Press PROGRAM.
9. Select a new job.
10. Select lowest number available or key in desired number.
11. Press OPTIONS until Label mode appears, then pressYES.
12. Enter first cut position.
13. Enter number of labels.
14. Enter label size.
15. Enter trim size.
16. If the backtrim is known, and to be executed every time, press YES.

30
 RETRIEVING A JOB FROM MEMORY

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.

< 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.
< Pressing "AUTOMATIC" will activate the job.
< 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.

5. Changes may be made to a program while in REVIEW MODE.

When the position to be modified is on the screen, press "OPTIONS."
< See PROGRAM MODE OPTIONS for details.

31
 SET UP ROUTINE

Χ 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 reprogrammed to operate on another
cutter or test fixture, as after repair.

< Every microcut7 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
1. Turn on power ADVANCED MANUAL MODE
OPTIONS FROM THIS POINT ON:
2. Select language
Ð
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 <10” 39. Japanese Sun enabled?
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.
correct?

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.

1.
TURN ON POWER

2. Select language[1] Select the language desired by pointing to the

→ English correct selection and pressing “YES.”
Espanol
Other OPTIONS . . . .

OR

1 2

3. Make sure all guards are in place. Inspect the

Are all guards in place? machine to ensure proper and safe operation, then
press “YES.”

YES

4. The leadscrew should be lubricated with light

Is daily lubrication machine oil and fluid levels and routine cleaning
completed? should be performed on the machine at this time.
Press “YES” when completed.

YES

34
5. 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.

YES

6. Do not press “AUTOMATIC” as though the cutter is

Press the AUTOMATIC ready for use. Instead, press “OPTIONS.”
key to calibrate!!

OPTIONS

7. Press “2” to enter the SET UP ROUTINE.

OPTIONS: [1]
→ Demonstration
Calibration & test
Previous screen

8. This memory test is nondestructive, so press YES.

Test memory?
YES or NO?

YES

35
9. If this is a new installation, or if contaminated
Save memory? memory is a suspected problem, press NO.
YES or NO?
If the job memory is valid, and not to be erased, press
YES.

This example will erase the memory.

NO

10. If the memory is to be erased, press “YES.”

Erase memory?
YES or NO?

YES

11. Select the units desired.

Select Units: [1]
→ Inches This example will press “1” for inches (or 2"
Metric for metric.)
Sun (Japanese)

OR
1 YES

36
12. Move the backgauge one inch (25 mm) while
Move the gauge one inch – watching the motor pulley.
does the drive motor turn
between 3 and 6 full turns? The pulley must turn at least 3, but not more than 6
turns. Press <YES> when the turns ratio is verified.

< 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.
YES

13. If the Clamp Sensor is properly installed, and the

CLAMP SWITCH CHECK
clamp is in the up position, press YES.

< The computer will then verify the Clamp Up

Sensor signal and either continue the "SET
UP ROUTINE" or display an error message.

YES

14. If a Cut Sensor is installed press YES.

CUT SENSING SWITCH
Is switch installed to sense
the cycling of the knife

YES

37
15. If the Cut Sensor is properly installed, and the knife is
KNIFE SWITCH CHECK in the up position, press YES.
Is the knife in the
Full up position? < The computer will then verify the Cut Sensor
YES or NO? signal and either continue the "SET UP
ROUTINE" or display an error message.

YES

16. Be certain that the backgauge is at least 10 inches

Is the backgauge at
(25cm) from the rear of the cutter, then press "YES.
Least 10 inches
from the max rear?
YES or NO? < The backgauge must be at least 10 inches
from the rear of the table to avoid damage
during this procedure.
YES

17. Press the “UP ARROW” key for a few seconds and
MOTOR DIRECTION TEST
observe the movement of the backgauge.
Use the UP ARROW key
Does the gauge move back?
YES or NO? < Encoder function may be verified by executing
the ENCODER TEST ROUTINE at this
point.

▲
18.
!!CAUTION!! Drive is < BE CAREFUL!!! The backgauge is under
operator controlled the control of the operator, and damage to the
Avoid collisions ! ! 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?
< The computer will automatically orient the
motor polarity as necessary.

OR
YES NO

20. The backgauge will now move toward the rear of the
Calibration routine! machine to trip the Rear Position Sensor.
Please wait !!!

< 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.)

< 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

Move the handwheel
an exact unit value. Type the exact current position
To an even value ---
and then press “YES”.
This position is .000 inches
EXACTLY
< 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.

< 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.

39
 This example will use 43 inches (110cm.)

4 3 YES

22. Use the DOWN ARROW Move the backgauge by pressing the “Down” arrow
To move the gauge to key until the gauge is within 10 inches (25cm) of the
knife, being careful not to drive the backgauge into
Within 10 inches of the
the clamp.
knife.

23.
!!CAUTION!! Drive is < BE CAREFUL!!! The backgauge is under
operator controlled the control of the operator, and damage to the
Avoid collisions ! ! machine and human injury are depending on
operator caution.

40
24. Is the backgauge When the key is released, the display will read “IS
less than 10 inches from THE BACKGAUGE LESS THAN ‘10’ INCHES
the knife? (25 cm) FROM THE KNIFE?” Press “YES” if it
YES or NO? is. If not, press the NO key and microcut will return
to the forward drive routine (step 22).

YES

25. Turn the handwheel forward until the

Move the handwheel
backgauge is at an exact unit value. Type the
To an even value ---
exact current position and then press “YES.”
This position is .000 inches
EXACTLY
< 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.

< 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)

5 YES

< 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).

< If a 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. Enter the maximum rear value.

Furthest position is:
Inches back.
< How far back can the backgauge travel before
running into the back of the machine?

This example will use 45 inches (115 cm)

4 5 0 0 0 YES

27. Enter the false clamp width.

False clamp width is
Inches across. < 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.

This example will use 3 inches (7,62 cm)

3 0 0 0 YES

28. Enter the minimum cut value.

Most forward cut is
3,000 inches long.
42
 < 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.

This example will use 1 inch (2,54 cm.)

1 0 0 0 YES

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

YES

< 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.

< Any of the questions asked after this point may be modified later in MANUAL MODE
OPTIONS without repeating the entire SET UP ROUTINE.

< Note that ADVANCED MANUAL MODE OPTIONS follows on the next few pages.

30. Enter the maximum speed that the backgauge will

Fast gauge speed is: travel in AUTOMATIC or SEMI-AUTOMATIC
Inches per second
43
 MODE.

< microcut will not allow a speed to be entered

that is greater than about one fifth the length
of the table.

< 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.)

5 YES

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.

< Slow gauge speed is purely a matter of operator preference.

< 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.)

1 0 YES

32. Enter MANUAL MODE ACCELERATION

In MANUAL MODE the
Acceleration rate is: 44
percent of maximum rate
 PERCENTAGE.

< How fast does the computer have to

accelerate to reach the programmed
maximum speed when the arrow keys are used
in MANUAL MODE?

< 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%

5 0 YES

33. In AUTOMATIC MODE Enter AUTOMATIC MODE ACCELERATION

the Acceleration rate is: PERCENTAGE.
percent of maximum rate
< How fast does the computer have to
accelerate to reach the programmed
maximum speed in AUTOMATIC MODE?

< Any percentage is legal, but 35-65% is the common range, and assures “smoother” starts to
extend machine life.

♦ This example will use 50%

5 0 YES

34. Enter AUTOMATIC MODE DECELERATION

Deceleration = %
PERCENT AGE.
Too high a value may
Cause vibration when
Slowing down!! 45
 < How hard does the computer have to step on
the brakes when trying to stop at a cut
location in AUTOMATIC MODE?

< Any percentage is legal, but 35-65% is the common range, and assures “smoother” stops.

< “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%

5 0 YES

35. BACKLASH ADJUSTMENT Enter BACKLASH CORRECTION value.

Gauge will move .000
in. behind target to < 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.

< 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 cm).

1 5 0 YES

36. CLAMP DRIVE CONTROL May the computer drive the backgauge toward the
Allow reverse drive rear of the cutter even when the clamp is still down?
With clamp down?
YES or NO? < 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 ? < 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.

< 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).

5 YES

38. In AUTOMATIC MODE Auto correction on or off.

If gauge knocked out of
Position, gauge will Press “YES” if the backgauge should correct its
Recorrect – YES or NO? position if it is knocked out of tolerance while in
AUTOMATIC MODE. If not, press “NO.”

YES

39. In AUTOMATIC MODE Select actual or artificially perfect position display.

Do you want to see the
True position? < A “YES” here will allow the true position of
YES or NO? the backgauge to be displayed when the
computer has stopped at a programmed cut

47
 position within the programmed settling
tolerance.

< 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.

YES

40. Select the number of digits to be displayed to the

11.753” or 11.75” right of the decimal point.
Do you want to see
The final digit?
< Choose “YES” if microcut is to display
YES or NO?
thousandths (3 digits after the decimal point)
or “NO” if only hundredths are desired (2
digits after the decimal point).

YES

41. Do you want the Should the “UNITS” key be able to select inches?
UNITS key to select
The inch display?
YES or NO?

YES

42. Do you want the Should the “UNITS” key be able to select old-
UNITS key to select the fashioned cutter’s fractions?
fractional display?
YES or NO?

48
♦ “42+ 7/16+ 0/64+ .004” as opposed to “42.441 in.”

< 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.

YES

43. Do you want the Should the “UNITS” key be able to select
UNITS key to select the centimeters?
centimeter display?
YES or NO?

YES

44. Do you want the Should the “UNITS” key be able to select
UNITS key to select millimeters?
the millimeter display?
YES or NO?

YES

45. Do you want the Should the “UNITS” key be able to select Japanese
UNITS key to select Sun?
the SUN display?
YES or NO?
49
 YES

46. Limit the key entry to Are only whole numbers, no fraction or decimal
whole numbers on the component, to be used?
left side of the display?
YES or NO?

YES

47. Should the power meter Is the power meter to be displayed during motor
Be displayed drive?
During motor drive?
YES or NO? < 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.

YES

48. Display the cut Is the length of the paper in front of the knife (the
length in front of portion that will be sheared off) to be displayed?
the knife?
YES or NO? < 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.

YES

50
49. Should microcut automatically eject the stock before
Do you want the
it drives backwards, so the operator does not have to
Gauge to push out
Before any reverse reach under the knife and clamp to handle the stock?
Drive after a cut?
< This is a great safety feature!

50. The distance of the If auto eject was turned on in step 49, how far should
auto eject movement the stock be pushed?
Should be:
In. < 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.

< 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).

5 0 0 0 YES

51. The SET UP ROUTINE is complete. The computer

Memory test
will now exit to MANUAL MODE and be ready for
In progress!!
use.

MANUAL MODE OPTIONS

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.

1. Enter the MANUAL MODE ADVANCED MANUAL MODE OPTIONS

2. Press OPTIONS to proceed from
each of the following screens to the Ð
next.
3. SELECT LANGUAGE A. STATUS SCREEN 3
1. Fast gauge speed
2. Slow gauge speed

B. STATUS SCREEN 4
52
 1) MANUAL MODE
acceleration rate
2) AUTOMATIC MODE
acceleration rate
deceleration rate
A. STATUS SCREEN 1 C. STATUS SCREEN 5
1) false clamp status 1) backlash correction value
2) calibrate gauge 2) allow reverse drive with the
clamp down?

B. KNIFE STATUS D. STATUS SCREEN 6

1) cut strokes on this blade 1) settling tolerance
2) last knife change date 2) auto correction

C. JOB MEMORY E. STATUS SCREEN 6

1) locations used 1) true or fake position
2) locations left 2) final digit on or off
D. Are the Programmed machine sizes F. UNITS STATUS
correct? 1) inch display enabled?
2) Fractional display enabled?
E. ENTER SERVICE CODE for G. UNITS STATUS
ADVANCED MANUAL MODE 1) centimeters enabled?
OPTIONS. 2) Millimeters enabled?
H. UNITS STATUS
1) Japanese sun enabled?
2) Left decimal (may only whole
numbers be used?)
I. MOTOR METERS
1) display power meter?
2) Display cut length in front of the
knife?
J. STATUS SCREEN
1) auto eject on or off
2) auto eject distance

MANUAL MODE OPTIONS DETAILS

1. Press “MANUAL” to ensure that the computer is in
87.312 in. MANUAL MODE.
MANUAL MODE
Job# 1 Cut# 1

53
 MANUAL

2. Press “OPTIONS” to access the MANUAL

87.312 in. MODE OPTIONS ROUTINE.
MANUAL MODE
Job# 1 Cut# 1

OPTIONS

3. Select language[1] Select the language desired.

→ English
Espanol < Other languages are available by pressing
Other OPTIONS . . . . “3” or “OPTIONS.”

OR
YES 1

4. STATUS SCREEN 1 [2] STATUS SCREEN 1

False clamp {ON}
→Calibrate gauge A. microcut will display the status of the false
Next screen Paper clamp.

< {ON} or {OFF} will be displayed, based on

the status of the False Paper Clamp Sensor.

54
B. 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, ½
inch short in the middle, and ¼ 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 ¼” (.65 cm), but never more
than 5” (12.7 cm).

C. To access the next options screen, press “OPTIONS” or “3”.

OR
OPTIONS 3

5. KNIFE STATUS
KNIFE STATUS: [2]
Cut strokes = 0000
A. CUT STROKES: Displays the number of cuts
→ Changed since microcut was last informed of a knife
Next screen change.

B. CHANGED: Displays the last date that

microcut was informed of a knife change.
< Press “YES” to inform microcut that the knife has been changed.

C. To access the next options screen, press “OPTIONS” or “3.”

OR
OPTIONS 3

6. JOB MEMORY: [3] JOB MEMORY

Locations used: 57
Locations left: 1943 A. LOCATIONS USED: Displays the amount
→Next screen of memory that has been used.

B. LOCATIONS LEFT: Displays the amount

of memory that is still available.

C. To see the next options screen, press “OPTIONS” or “3.”

OPTIONS
3 55
 OR

7. MACHINE SIZES:
MACHINE SIZES
45,000 in. Maximum
A. Extreme rear position that the backgauge
3,000 in. Clamp
may reach (maximum table length).
1,000 in. Minimum
< How far back can the backgauge travel
before running

B. 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.

C. 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.

D. To access the next options screen, press “OPTIONS”.

OPTIONS

8. Further options are available only with the authorized

Please enter your service 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.

ADVANCED MANUAL MODE OPTIONS

9. STATUS SCREEN 3 [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 “3”.
OPTIONS 3
57
 OR

10. STATUS SCREEN 4 [1] To adjust rate of acceleration in MANUAL MODE:

→ Manual accel = 10% See page 48, step 32
Auto accel = 40%
Next screen To adjust rate of acceleration in AUTOMATIC
MODE: See page 48, step 33

< 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.”

OPTIONS OR 3

11. STATUS SCREEN 5 [1] To adjust the distance that microcut will travel to
→ 0.150 in. Backlash correct for backlash (leadscrew play):
Clamp drive {ON} See page 49, step 35
Next screen
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.”

OR
OPTIONS 3

12. STATUS SCREEN 6 [2] To adjust the settling tolerance:

→ Settling @ .005 in. See page 50, step 37
Correcting {ON}
Next screen To enable or disable auto correction:
See page 50, step 38

To see the next options screen, press “OPTIONS”

OPTIONS 3
or “3”.
OR

58
13. STATUS SCREEN 7 [1] To enable the true position or artificially perfect
→ True size {ON} display: See page 51, step 39
Final digit {ON}
To display thousandths or only hundredths:
Next screen
See page 51, step 40

To see the next options screen, press “OPTIONS”

OPTIONS 3 or “3.”
OR

14. UNITS STATUS [1] To enable or disable inches: See page 51, step 41
→ Inches {ON}
Fractional {ON} To enable or disable old fashioned cutter’s
Next screen fractions: See page 52, step 42

To see the next options screen, press “OPTIONS”

or “3.”
OPTIONS 3
OR

15. UNITS STATUS [1] To enable or disable centimeters:

→ Inches {ON} See page 52, step 43
Fractional {ON}
Next screen To enable or disable millimeters:
See page 52, step 44

To see the next options screen, press “OPTIONS”

OPTIONS 3
or “3.”
OR

16. UNITS STATUS [1] To enable or disable Japanese sun:

→ Sun {ON} See page 53, step 45
Left decimal {ON}
To enable or disable the entry of decimals:
Next screen
See page 53, step 46

To see the next options screen, press “OPTIONS”

OPTIONS 3 or “3.”
OR

59
17. MOTOR SCREEN
STATUS METERS [1] To enable or disable the power meter display:
→ Power
Inches meter {ON} See page 53, step 47
Fractional
Front cut {ON}
Next screen 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”

OPTIONS 3 or “3.”
OR

18. MOTOR METERS [1]

→ Auto eject {ON} To enable or disable the automatic stock eject after
Distance: {ON} a cut, before driving backwards:
Next screen 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 3
“OPTIONS” or “3.”
OR

®
microcut
60
 service manual

SERVICE AND TROUBLESHOOTING

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
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) If the display asks for a language selection, then go to step 3. If not, then
a) If the screen only shows one blinking square (cursor) in the top left corner of the display,
replace the display side 80535 microcontroller.
b) If the display shows the key test routine, check for a stuck <+> key.
c) If the unit beeps like it is working, despite the blank screen, replace the screen.
d) Repair or replace the console.

3) If the keys respond 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) If the 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) If there is an 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) If the computer does not respond to the language selection, then replace the drive side
80535 microcontroller.

62
5) If the backgauge moves (either direction, even a little bit) when <AUTOMATIC> is pressed,
then go to the next section. If not, then
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.

6) If the backgauge goes backward, then go to step 7. If not, then

a) If the backgauge goes forward, perform the SET UP ROUTINE.
b) If the screen says No Motion Seen after some motion, then check 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.

7) If the backgauge stops when the position sensor is tripped, go to step 8. If not, then
a) 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
b) 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.
c) 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) If the system does not ask for a new calibration value at this point, go to step 9. If it does,
then
a) Enter the correct current position of the backgauge.
b) 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) If the backgauge drives in high speed, go to step 10. If not, then

a) 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.
b) Be certain that the clamp up sense is not covered.
c) Be certain that the motor turns at least 3 times, but not more than 6 times for each inch of
backgauge travel.
d) 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.
e) Be certain that the transformer is connected to the correct AC input voltage.
f) Be certain that the correct motor was used for this size machine. Contact GMS for
details.
g) 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) Be certain that the motor turns at least 3 and not more than 6 revolutions for one inch (25
mm) of backgauge movement.
b) Make sure that the programmed settling tolerance is not too small. This may be
reprogrammed in the MANUAL MODE OPTIONS if necessary.
c) Be certain that the motor belt tension is correct. Typically, tight belts will cause settling
problems.
d) Check for a bind in the backgauge.
e) Check for leadscrew flex back.
f) Perform the SET UP ROUTINE to get microcut learning the dynamic, inertial, and
frictional settling parameters eagerly again.
g) 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 SET 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 180Ε,
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) If all strips are equal, then microcut is calibrated.
ii) If the 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) Be certain that neither the shaft encoder sprocket or the leadscrew sprocket is loose.
Check for alignment.
g) 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) Be certain that the motor turns at least 3 and not more than 6 revolutions for one inch (25
mm) of backgauge movement.
b) Noise during acceleration-Decrease the acceleration percentage in the MANUAL
MODE OPTIONS.
c) Noise during deceleration-Decrease the deceleration percentage in the MANUAL
MODE OPTIONS.
d) Be certain that the motor mounting plate is secured directly to cutter (not extended with
threaded rod) with at least three bolts.
e) Be certain that backgauge moves freely with handwheel (no binding)
f) Be certain that the backgauge brake is fully released at all times
g) If vibration occurs at high speed, be certain that the backgauge carriage and leadscrew
are secure.
h) Be certain that the motor belt is not too tight.
i) Be certain that the transformer is wired to two of the incoming power phases (not to the
neutral line)
j) Be certain that the correct motor is being used.
k) 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) Increase the settling tolerance in the MANUAL MODE OPTIONS.
b) 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
 PROMPT ERROR MESSAGE LIST
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

The main computer has not powered up properly. Turn

FAILURE RECOGNIZED power off and count to ten. Try turning power on again.
Main CPU has failed Service may be required.
to power on properly
restart microcut !!

Try turning the power off and on again. Service is

FAILURE RECOGNIZED probably required.
Job memory is losing
data—service needed
before operating !!

Memory pertaining to the type of cutter microcut is

Encoder direction installed on has been lost. It will be necessary to go
data has been lost !! through the SET UP ROUTINE to correct this.

A key appears to be pressed in during the start up

A key appears to be procedure. Refer to TESTING THE KEYBOARD to
pushed. Check keys. verify which key this is.
Refer to KEY TEST in
OWNER’S MANUAL

The data that allows microcut to operate on this machine

Calibration lost 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

Turn power off !! which requires a full restart to recalibrate. Turn the power
Restart required !! off, then back on and press <AUTOMATIC> to start.

Either the backgauge is tripping the position sensor at

Position sense error 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
 The SET UP ROUTINE must be fully completed before
INCOMPLETE SETUP !! continuing.
Follow procedure all
the way through---DO
NOT TURN POWER OFF

PROGRAMMING PROMPTS

This prompt warns the operator of remaining job memory

Cut positions space if that space is less than 100 positions.
available:

All of the available job memory has been used.

Note that while microcut has the option for an almost
Out of memory!! 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
Job # already used number or erase this number before programming.

microcut is looking for the last programmed job while

in the REVIEW MODE.
Searching last job#

microcut has shown all of the programmed jobs while

in the REVIEW MODE.
End of search!!

microcut was not able to locate the requested job in

memory.
Job not found!!!

microcut does not have enough unused job memory

available to program the number of stops requested in
Not enough memory!! 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 this 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
Calibration error is
made. It may be necessary to perform the SET UP
too great!! ROUTINE or the rear position sensor may need to be
moved forward.

OPTIONS ROUTINE MESSAGES

The proper service code is required to go further. This

Please 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 OUT ***
position and microcut will still recognize the cut
sensor if the knife is operated.

The position that was requested is beyond the physical limits

Too FAR forward!!! of the table.

The position that was requested is beyond the physical limits

of the table.
!!Too FAR back!!
< microcut limits the prompt display to realistic
values as the number keys are pressed (if the
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 rear. However, if the final result calculated is larger than
the maximum rear value this prompt will show. If a 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
 The fraction when using the calculator keys cannot
Cannot be zero!! 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
Number too small!! FORWARD!!!).

The sum of numbers when using the calculator keys is

Number too big!! 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

CLAMP DOWN!! registers does not agree with the others
regarding the position to which microcut should
drive.
< 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!! 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
Drive error!

The gauge has moved in the wrong direction for too

long. Try again or go through the SET UP
KNIFE DOWN!!
ROUTINE.

microcut has not detected any motion during a period

No motion seen!! 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.

FAILURE RECOGNIZED microcut has not sensed 115 V AC for the drive
110 VAC power missing 70
Check transformer
 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.
Service accordingly.
False zero detection
on the AC power line
Check brown outs!!

FAILURE RECOGNIZED A power disturbance has caused a data error in the

Over voltage state main computer. It will be necessary to power down
and restart the system to insure proper cutting accuracy
on AC power. Check
Supply line status

ERROR – Power These three screens indicate that microcut has

diagnosed an error in counting. Check or replace the
Interruption. Data
connection between the display console and the shaft
Has been lost. Turn encoder. Turn the power off and restart microcut.
Power off -- restart Refer to SERVICE AND TROUBLESHOOTIING

Zero-set error!!
ORcounts seen
Too many
microcut has diagnosed an error in counting. Check the
connection between the display console and the shaft
Zero-set missed! encoder. Turn the power off and restart microcut. Refer to
other parts of this manual for assistance.

Zero-set occurred too

No motion
early!seen!!

CALIBRATION & TEST ROUTINE PROMPTS

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.

< 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.

The NO key has been pressed in response to one of

Make adjustments microcut's switch checking questions in the SET UP
To continue!!! 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

The clamp switch has a is should be up or the clamp switch did not operate
wiring error!! 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

!! TURN POWER OFF !!
continuing. Read the other prompts which alternate
Corrections must be made in with this one to determine what needs to be corrected.
order to go further!

Either the CUT sensor is broken, unplugged, or the

The cut switch has a knife is down during the SET UP ROUTINE or
wiring error!! 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

The position sense has covered during the SET UP ROUTINE or another
a wiring error!! sensor is shorting out the position sense line.
Corrections will need to be made before continuing.

The shaft encoder is microcut has determined that the encoder gearing is
turning too quickly. incorrect. It will be necessary to change the sprockets
change gearing for 2 in order to correct this.
to 4 turns per inch

The shaft encoder is microcut has determined that the encoder gearing is
turning too slowly. incorrect. It will be necessary to change the sprockets
change gearing for 2 in order to correct this.
to 4 turns per inch

Mechanical changes This will appear after another clarifying prompt if

are required for the certain requirements have not been met.
installation to be
to specification!!
Encoder turns ratio is There are too many turns of the encoder for microcut
too great for mm
calibration on this 72
machine – use cm!
to calibrate this machine in mm during the SET UP
ROUTINE. Use cm instead

73
 TESTING THE KEYBOARD

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 the KEYBOARD TEST ROUTINE when power is turned on if
"+" is stuck in.

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 TESTING THE ENCODER

microcut contains an ENCODER TEST ROUTINE to verify that the computer is receiving positioning
information from the encoder.
< This test may only be executed from within the SET UP ROUTINE, at the motor direction test
step.

MOTOR DIRECTION TEST 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 < This number does not correspond to inches,
cm, mm, or Japanese sun, it is just quadrature
information from the encoder.

Χ Turn the handwheel backward and forward and observe the count display.

< 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)

< 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.

Χ The display should show a change of two-thousand counts every time the encoder completes a
revolution.

< 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.

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 TESTING THE PROXIMITY SENSORS

microcut contains a PROXIMITY SENSOR TEST ROUTINE to verify that the computer is receiving
information from the proximity sensors.

< 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.”

+ / OPTIONS

X if covered: POS=_ The display will then show the status of all four
CUT=_CLAMP=X FPC= sensor signals

Χ 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.

Χ A __ will appear if the computer is not receiving a signal indicating the presence of metal less
than 2 mm from its sensing surface.

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?

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 FACTORY PHONE SUPPORT AND
RETURNS FOR SERVICE

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 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.

< The more information that you provide with the return, the more effective our service will be.

GRAPHIC MACHINERY & 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

77
 MICROCUT REPAIR RETURN AUTHORIZATION SHEET
RMA #
SENDER
Company
Street
City Stat Zip
Phone Number Fax Number
Contact name
Purchase Order Number

List all parts being shipped Serial numbers

Symptoms/Instructions

78
 Υ Mark one for preferred return shipping method

Sonic Air (8 hour air courier) $180 to $250

Overnight (RED) Next business day delivery

Overnight (RED) Saturday delivery

2 day (BLUE)

3 day (ORANGE)

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

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