microcut

Owners Reference Manual for the

PLUS & COLOR WS Wide Screen
Paper Cutter Automation Systems

Petaluma, CA USA Phone 707-776-4500 FAX 707-776-4555

e-mail [email protected]
www.cp-microsystems.com
Last revised 10 March 2014

Date of installation
Installed by
Machine manufacturer
Machine model
Machine size
Machine serial number
microcut serial number
Extras

Notes

microcut, microfacts, and cutternet are registered trademarks of C&P Microsystems, LLC.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION THAT 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 C&P MICROSYSTEMS. ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT
NOTIFICATION. C&P MICROSYSTEMS ASSUMES NO LIABILITY FOR OMISSIONS IN THIS DOCUMENT
OR FROM THE USE OR MISUSE RESULTING FROM INFORMATION CONTAINED WITHIN.
NOTE: Revisions occur as requests are made from operators, supervisors, and others. This manual may be
incomplete. Refer to our website referenced on the cover sheet for updated material.

TABLE OF CONTENTS
Due to the similar operator interface and components this manual is for both the PLUS WS and COLOR WS
control systems. The unique features on the PLUS WS model are identified here and in the document.

CHAPTER

SUBJECT

PAGE

Operation
Introduction
Power On
The Screen
Operation Manual, Program, Review, Automatic
Programming a New Job
Target Options
Programming Options
Labels
Sheet Divide
Reviewing Existing Jobs
Converting a JDF or PPF or CIP3/4 Job **
Back Gauge Options
Clamp Options
Networking Options **
Operator Options
Setting the Time Clock
Microfacts Options **
System Options
Selecting Programming Options
Maintenance Options
The Machine Set Up Screens
The Clamp and Knife Set Up Screens
The Utilities Screen

4
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
30
31

Error Messages
Status Indicators From The H3 Drive Computer
The H3 Board
H3 LEDs
H3 LED Definition Table
H3 Terminal Connection Table
PLUS WS Component Map

32
33
34
36
37
38
39

Installation Basics For The Back Gauge Control System

System Overview
Basic Layout
Optional Auxiliary Controls
Sample Installation Diagram
Recommended Tool List
The Mechanical Installation
Wiring And Power
Special Notes
Final Check

40
41
42
43
44
45
46
54
55
56

Optional Expansion Board Control Package

The Expansion Board
Expansion LED Definition Table
Expansion Terminal Connection Table

57
58
59
60

Specifications / Limitations
CE Declaration Of Incorporation
Notes

62
63
64

Additional Information

Installation - microcut

Expansion Board

Details

** These features are available only on the PLUS WS. They are not applicable to the COLOR WS unit.

INTRODUCTION
Thank you for purchasing a microcut control system for your paper cutter. Having done so, you
have joined tens of thousands of microcut users worldwide who are enjoying the benefits of
computer-controlled cutting. microcut is a state of the art system for controlling back gauge
movement, with an intuitive, easy to use operator interface. After turning the power on and getting
started, there are four basic operating methods

Manual operation.
Programming new jobs.
Reviewing existing jobs.
Automatic operation using an existing job.

Many of the features you will find in microcut have resulted from operator's ideas throughout the
world. If you have any suggestions, we encourage your input. Where possible, we will make the
revisions and update your unit. Our special thanks to all who have helped make microcut the world
leader in cutter automation.

Requirements for installation and use:

The machine is to conform to present safety requirements in your area.
Supplied power is to be 110/22010% VAC, 50/60 Hz protected by a 15 or 20 amp breaker.
The installation is to be performed per the instructions included in this manual.
All of the safety elements must remain intact and correctly functional.
All nip, pinch, crush, or cutting zones must be properly guarded.
A paper cutter can be a dangerous machine. Only properly trained and supervised
personnel should operate this equipment.

POWER ON
At power ON the computer will take a minute or so to boot up. The screen will go black for a period
as the computer loads the screen drivers. This is normal. Then the Start-Up screen will appear:

to enter
the
Set Up Routine.

Tap

Tap

See page 25.

to start the
system.

Software dates are in lower

portion of ball.

Tap
to change
the language.
See page 19.

will appear on the screen and the

back gauge will drive to the back to
calibrate.

Tap

only for an emergency stop.

THE SCREEN
The fundamentals of the screen repeat in all operating modes. Tap on different areas of the screen
to select various operations:
Back gauge position and units:
Relative
back gauge
position.

Air table ON if
jets are
shown.
Tap the table
to change.

RED if operations are disabled.

GREEN if in position and all
operations are OK.
YELLOW if operations are OK
but no position is defined.
WHITE if only the clamp is
enabled.
Tap POSITION area to transfer
that number to calculator.
Tap UNITS area to change units.

Language
and Operator
Preferences.
Knife
UP or
DOWN.

Time
and
Date.

Network
Set Up.

microfacts
menu.
PLUS WS
ONLY

PLUS WS
ONLY

Red if
DOWN.

Clamp
UP or
DOWN.
Red if
DOWN.

Hand
wheel IN
or OUT.
Red if IN.

Operator
Options.

Tap this and

then any other
part of the
screen to get
information on
any icon.

Air motor
ON / OFF.

MANUAL, PROGRAM, REVIEW

and AUTOMATIC modes.

Tap to
change.

See next page.

Calculator keys to
enter numbers.

BACK GAUGE drive control:

BACKWARD.
Maintenance
Options.

Target Data Box shows the programmed

targets:

Icons to the left are the Target

options. See page 9.

Icons to the right are the

Programming options. See page 10.

Auto Correct will HOLD position.

MOVE to the keyed in position.

FORWARD.

NOTE: Depending upon the set up of your system, some of the icons shown above may not appear on your screen.

OPERATION
There are four basic operating modes:

MANUAL
Tap

for MANUAL mode. This is used to position

the gauge one cut at a time. Use

and

and

OR

to position the gauge. See page 22.

PROGRAM
Tap
for PROGRAM mode. This is used to define a
job number and program targets to be cycled through in
AUTOMATIC mode. The entry screen allows job number
selection. The system then advances to the programming
screen virtually the same as the Automatic screen shown
below. See page 8.

REVIEW
Tap
for REVIEW mode. This is used to retrieve
previously programmed jobs or data from a USB memory
stick or the local network. See page 13.

AUTOMATIC
Tap
for AUTOMATIC mode. This is used to cycle
target to target through the selected job to perform the
necessary cutting operations.
NOTE - To enter AUTOMATIC you must have already done one
of the following:
Made a new job in PROGRAM
Selected an old job in REVIEW
Been in AUTOMATIC with a current job.

PROGRAMMING A NEW JOB

Tap

to enter PROGRAM mode.

Use
Tap

to select a job number.

to exit or tap

to continue.

NOTE: Tap
when the job number line is blank and the
computer will assign the lowest available job number.

The Job Programming screen will appear.

Use
to enter data, or move the gauge and cut,
select options for alternate programming methods.

or

Refer to Target Options (to the left of the job data box) and
Programming Options (to the right of the job data box) on
the next two pages for details.

Messages that may appear include:

The system will not let you program a
job if the number is already used.
If defined in the Machine Set Up
screen to give a warning, the clamp
pressure reminder screen will appear.

Jobs can be copied or renamed if you

want.
Jobs can be protected if desired. If
the protection feature is used an
operator code will be required before
changes can be made. The job can
still be copied to another number.

TARGET OPTIONS
When a target type is activated a green box will appear around the icon. Tap an icon to select it.
Several target icons may be activated at one time. For instance, a cut could be a quick cut and a cut
optimization and an auto waste removal. Tapping an icon may shut off another icon (clamp would
shut off all cut options). The available target types are dependent upon the machine and the
installation. These are defined in the Set up Routine. Some of the following icons may not appear
on your screen.
Target types can only be changed when entering a new target
Knife Enabled

or

if you tap

(Change target).

Knife NOT
Enabled

CLAMP

CUT
The knife will operate normally.

QUICK CUT
So you can release the cut buttons
during the cut.

Clamp is enabled, Knife is not.

AUTO CLAMP
After the first clamp is started.

CLAMP PRESSURE

AUTO CUT
After the first cut is started.

At this target. If 0, then only the

knife will operate during cutting.

CUT OPTIMIZATION

LOAD

Allows the clamp to stop before

going all the way up.

Clamp is enabled, Knife is not.

PUSH

CLAMP TO JOG
Keeps clamp down after cut so you
can jog the stock back into position.

Goes to the target and then

immediately goes to the next
target.

AUTO WASTE
REMOVAL
Clamps, opens the table, cuts,
pushes, closes table, moves to next
target.
Knife is disabled ONLY if your machine is so equipped.

PROGRAMMING OPTIONS
The COLOR WS and PLUS WS has several options for programming a job. The icons to the right of
the job data box allow you to select from a number of choices. These options can be enabled or
disabled. Only those options that are enabled will appear on the screen. Some of the below options
may not appear on your screen. Refer to the section titled Selecting Programming Options in this
document for details.

CHANGE

COMMENT

Change a target value.

Add a comment under the target.

INSERT

JOB PROTECT

Insert a target BEFORE this

location.

Lock a job (protect from

changes) or unlock it.

COPY JOB
DELETE
Delete a target.

LABELS
Begin a one or two sided label
program.

Copy the job to a different

number. NOTE: To simply
CHANGE the number, Tap the job
number in the Target Data Box.

STAR
Mark several cuts for group
editing. Press and hold for a
second to mark ALL of the
targets for change.

SHEET DIVIDE
Divide a sheet into equal sizes.

LAY COMP
For one lift ONLY

LAY COMP

Adjust all forward moving cuts

by the same amount.
Available only in AUTOMATIC
mode.

Adjust all forward moving cuts by

the same amount. Available
only in AUTOMATIC mode.

10

LABELS
LABEL mode allows multiple targets to be calculated by entering a few details. Labels can be saved
as individual cuts (every target is calculated and saved) or as raw data (start position, number of
labels, label size, and trim size). Saved as individual targets, every position can be modified as
necessary. Saved as raw data the trim size can be adjusted to compensate for sheet stretch.
The memory available in the PLUS WS display is, from practical points of view, limitless. To that
end, it does not matter which way you store the label data. Choose the method that works best for
your operation and comfort.
Tap
to start programming the labels on Side 1. The target type and attributes can be selected
from the list on the left side of the display. For instance, you may opt for AUTO CUT, CUT
OPTIMIZE, or AUTO WASTE REMOVAL (which will be programmed at only the trim targets).
Enter the first cut size.

OR position the
Use
and
gauge and make the cut.
Enter the number of labels on this
side (or strip).
Enter the label size.
Enter the trim size.
NOTE: After you fill in ANY three lines the remaining line will be calculated automatically. For
instance, you might skip the first cut if you did not know it (17 labels of 2+3/64 with a trim makes
the first cut difficult to calculate).
Tap

Tap
Side 2.

to flip it to

(and vice versa).

This defines if the first cut will be saved in the job or not.

to complete the label programming OR tap

to abort OR tap

to go to

Program Side 2 in the same way you did Side 1.

Tap
Side 1.

to go back to

to complete
Tap
programming OR
Tap

the

label

to abort.

11

SHEET DIVIDE
SHEET DIVIDE will equally divide a sheet into multiple (equal) logs. Tap
to start dividing the
sheet. The target type and attributes can be selected from the list on the left side of the display. For
instance, you may opt for AUTO CUT, CUT OPTIMIZE, etc.

Enter the sheet size.

Use

and

OR position the gauge and make the cut.

Enter the number of times you would like to divide the sheet.
Tap
Tap

12

to flip it to

(and vice versa).

to complete the SHEET DIVIDE OR tap

This defines if the first cut will be saved in the job or not.
to abort.

REVIEWING EXISTING JOBS

REVIEW mode allows you to recall jobs on the display drive, USB memory stick, and local area
for REVIEW mode.

network (network connection required). Tap

This column shows
job location.

Cutter

Tap the Job number or Date

column to SORT by that column.

USB

Tapping this will

SUB-SORT via job
location.

Network

Sorted column is GREEN.

The PREVIEW area shows the first few targets on

the highlighted job.
If the bubble is over an unconverted CIP file (see
next page) then you will be advised accordingly.

Tap

for Network setup.

Tap

to Copy selected job(s) to USB.

Tap

to Select one or several jobs. Hold to select all. Can be used for DELETE or COPY.

Tap

to Search within the sorted (GREEN) column (Job number or Date).

Tap
Tap

or

to Highlight the job you want.

to Delete selected job(s).

Tap
to review the full job. This transitions you into PROGRAM mode so you can view and
edit the job as desired. Also refer to CIP Jobs.
Tap

to use the highlighted job in AUTOMATIC mode.

13

CONVERTING A JDF OR PPF OR CIP3/4 JOB (PLUS WS ONLY)

Files stored in jdf, ppf or CIP3/4 formats can be imported to the computer through either a flash
memory stick or through a network system if the computer is connected up for this. All jobs will be
available (local, memory stick, or network).

for REVIEW mode.

Tap

Move the bubble to the desired CIP job to

begin the data conversion process and
(a preview of the job) will appear
Tap
to define the parameters
that will allow the cuts to be calculated.

Compare the image on the screen to the printed sheet as it will be loaded into the cutter. The bottom buttons
will adjust the screen image.

Tap
other side.

to move the guide to the

Tap
side.

to flip the sheet over side to

Tap
bottom.

to flip the sheet over top to

Use the buttons to make the image match

the sheet to be cut.
You can opt to have the system program a load point or not. The load point will be positioned so that roughly
12 of stock will be in front of the knife (based upon the parent sheet size specified in the CIP file). You can
insert your own load point from the Automatic Screen as well.
You can opt to have the targets programmed to make only cuts that leave the signature behind the knife. Due
to the shape of the knife the material to the front of the knife is ripped apart while the material behind the knife
is cut. For the highest quality cutting the signature should always be behind the knife. But this will require
more turning and manipulation of the stock. For the quickest production you may wish to not require this
feature.
You can also split the sheet into two jobs. In some cases you may wish to split the sheet and cut only half of
the job at a time (sheet size is too big for the cutter or the job is being transitioned to a different cutter to be
completed). In this case Tap

.
See the next page.

14

Once you Tap

you can now touch
the screen at the location where you want to
split the sheet. Assuming that the cut can
be made at that point without cutting
through a signature, the screen will show
the selected splitting line.
Tap

to continue OR Tap

to exit.

The screen will change to ask if you want to program one side and then the other, or keep only one of the two
sides. Move the bubble to the selection you would like.
Tap

to continue OR tap

to exit.

Tap

to trim all 4 sides.

Tap

to trim just the first 3 sides.

Tap

to trim just the first 2 sides.

Tap

to trim 3 sides with a 180 flip.

How you trim will affect the order in which

the job must be cut.
Tap

to continue OR tap

to exit.

The screen will indicate the job is being created. Then the completed job will be displayed. Each cut will have
a comment attached to help guide you through operation. These comments include cut, rotate (left, right, or
half), store, ship, and more. The system will proceed to the Program screen allowing you to add, delete, or
adjust target values.

The created job can be modified in the

same manner as any other job if revisions
are required.

Tap
to use the highlighted job in
AUTOMATIC.

15

BACK GAUGE OPTIONS

Tap
for
BACK GAUGE options.

Use
or
want to select.

to highlight what you

Use

to enter new values.

and

For options that are ON or OFF use

or
Tap

to adjust the selection.

to exit.

OPTIONS

DESCRIPTION

Auto eject

Pushes paper FORWARD every time back gauge changes to reverse.

Forward speed

Maximum speed of FORWARD moving back gauge.

Reverse speed

Maximum speed of REVERSE moving back gauge.

Push out speed

Maximum speed of FORWARD moving back gauge during a push.

Deceleration rate

How quickly back gauge stops after FORWARD speed.

Tolerance

Allowable window size of target position.

Calibrate Gauge

Make minor adjustments to back gauge position.

Manual drive micro

positioning

Tapping

Sideloading

Paper is loaded from the rear of your machine.

Auto advance after sideload

After paper is loaded, the back gauge moves to next target.

16

or

will move the back gauge the minimum increment.

CLAMP OPTIONS

Tap
for
CLAMP and KNIFE options.

or
to highlight what
Use
you want to select.

Use
values.

and

to enter new

For options that are ON or OFF use

or
Tap

to adjust the selection.

to exit.

OPTIONS

DESCRIPTION

Cuts on this knife

Knife cycles since last knife change.

Clamp pressure

Adjust clamp pressure. Requires a proportional valve in the clamp

hydraulic control and either the Expansion board or the B65 full paper
cutter control system.

Auto Clamp timeout

Time clamp is DOWN during Auto Clamp.

Clamp Lead

Time between clamp DOWN and knife start.

Clamp release time for

cut optimization

Time of clamp rise after cut. This requires either the Expansion board or
the B65 full paper cutter control system as well as a clamp locking / enable
valve.

17

NETWORKING OPTIONS (PLUS WS ONLY)

Cutternet (software and hardware in the PLUS WS system) can connect to your LAN (Local Area Network).
This procedure should ONLY be performed by your authorized computer maintenance person.

Tap

(Network ENABLED) or

(Network DISABLED) to

Use
address.
Tap

to enter your server or workstation name or

to exit or

Use
directory name.
Tap

to back up or

Use
Tap

access the network connection features.

to continue.

to enter your server or workstation shared

to continue.

to enter your network user name.

to back up or

Use

to continue.

to enter your network user password.

Tap

to back up or

Tap

to not enable the network.

Tap

to enable the network operation.

to continue.

Use
or
to locate the bubble over the selection you require.
FTP is File Transfer Protocol and may be required for non-PC type networks.
If you require FTP then select the type of FTP you use (active or passive).
NOTE: If you select Active FTP you will be presented with another screen for Fuji
Mode On or Fuji Mode Off (Fuji mode is specific to a particular Fuji plant). Select

Fuji mode Off.

18

Tap

to enable this operation.

Tap

to disable it and program normally.

OPERATOR OPTIONS
The COLOR WS and PLUS WS display contains several languages.

Tap

Use

to change the language.

or

to move the bubble over the language you desire, then tap

If the microfacts time management system is activated the next screen will request Operator Log In.
Otherwise you will return to the operation you were last performing.

19

SETTING THE TIME CLOCK

The COLOR WS and PLUS WS display contains a time clock for tracking events.

To change the time and date, tap

(the screen area where the time and date is shown).

Use

to enter the correct time.

Select AM, PM, or 24 (hour) time mode to

continue.

Use

to enter the correct date.

Tap mm/dd/yyyy (Month / Day / Year) or

dd/mm/yyyy (Day / Month / Year) for the
display method and to exit.

20

MICROFACTS OPTIONS (PLUS WS ONLY)

The PLUS WS display contains software called microfacts. This can be used to track many
operations of the machine. This is tracked in the background as the operator selects different
operating modes and runs through jobs or other procedures. You can also use this feature to limit
access to the machine (when Operator Codes are enabled only personnel with valid codes can use
the system) or control what features are available to various operators.
To access the microfacts features tap

You must have a valid access code to enter the microfacts screens.

Use

Tap

to display your code.

to exit; or tap

or

Use

to continue.

to position the bubble on the line you would like

to adjust, then tap

OR..Tap

to exit the screen.

NOTE: Exiting this screen implies a new Operator Log In. If the Operator
Access Codes are enabled you will need to enter a valid code to continue.

Use
Tap

to enter your code.

to continue.

Enter/Edit Operator Codes

From here you can enter up to 12 different operators defining access rights to
Back Gauge Options, Clamp & Knife Options, Networking, Time Clock,
microfacts, Operator Preferences, Toolbox Options, Program Mode, Review
Mode, and Automatic Mode. Follow the instructions on the screen to enter
each choice.

Enter/Edit Management
Code

From here you can modify you microfacts management code.

Enter/Edit Idle Time

Microfacts Reports
Microfacts is enabled or not
Idle Time is enabled or not
Add, Edit, Delete E-mail
Addresses

From here you can define idle time as 5 to 30 minutes as well as select from a
group of idle time reasons or key in your own. If no machine use is seen for the
idle period a screen of reasons will appear and require that a selection be made
before operation can continue.
Use this option to define report filters (none, by operator, by job, or by operator
and job), select if the report should be summarized or detailed, and if it should
be exported to USB memory stick, network, or via e-mail (which can also be
defined on this screen). The report can also be viewed on the display itself.
Options will not be shown for non-existent devices.
From here you can determine if you will track the operations of the cutter or not.
From here you can determine if you will activate idle time or not (require
reasons for idle time to be entered when the time entered above is exceeded
without operation).
From here you can add, edit, or delete addresses to send the microfacts time
reports to. You can also define automatic daily reporting from here as well.

21

SYSTEM OPTIONS
To enable, disable or modify various options, tap
Tap
An

(MANUAL mode).

to open Operator Preferences.

X over an icon indicates it is disabled.

Tap the icon to change the status.

RIGHT COLUMN
Screen saverOFF to 3 to 5 to 7 to 9 minutes.
Gauge power metershown as a % next to the gauge icon.
Keyboard choiceQWERTY or Alphabetical.
Decimal point Determines method for number entry.

Tap

to exit.

Tap

to change the icon display to pictures (in all screens).

Tap

to change the icon display to words (in all screens).

LEFT COLUMN

Allows inch measurement .

Allows cm measurement.
Allows mm measurement.
Selects 2 or 3 places after the decimal point (1 or 2 if mm).
Tap

22

to exit.

SELECTING PROGRAMMING OPTIONS

CHANGE

COMMENT

Change a target value.

Add a comment under the target.

INSERT

JOB PROTECT

Insert a target BEFORE this

location.

Lock a job (protect from

changes) or unlock it.

COPY JOB
DELETE

Copy the job to a different

number. NOTE: To simply

Delete a target.

CHANGE the number, Tap the job

number in the Target Data Box.

LABELS

STAR

Begin a one or two sided label

program.

Mark several cuts for group

editing.

SHEET DIVIDE
Divide a sheet into equal sizes.

LAY COMP
For one lift ONLY

LAY COMP

Adjust all forward moving cuts

by the same amount.
Available only in AUTOMATIC
mode.

Adjust all forward moving cuts by

the same amount. Available
only in AUTOMATIC mode.

From PROGRAM and AUTOMATIC you can enable or disable various options.
Tap

to open Operator Preferences.

over an icon indicates it is off and will not appear during

An
operation.
Tap the icon to change the status.

23

MAINTENANCE OPTIONS
The COLOR WS and PLUS WS display tracks knife strokes and time to evaluate when maintenance
is due. Warnings will appear on the screen as necessary. To perform maintenance items and
update the alarm timers tap

to select Maintenance (knife) options.

Use
or
to
highlight what you want to
select.

will appear to select

the choices as you move
the bubble.

Tap

OPTIONS

to exit.

DESCRIPTION

Cuts on this knife

Press to 0 (zero) the cut counter.

Knife down auto stop

Stops knife DOWN. This requires the B65 full paper cutter
control system.

Manual hand crank knife

change

Allows manual movement of knife. This requires the B65 full

paper cutter control system.

Clean knife

Stops knife DOWN and releases clamp UP. This requires the
B65 full paper cutter control system.

Knife change

Instructions, if available, for your machine. This requires the

B65 full paper cutter control system.

Knife Auto Set

Starts the routine to automatically set the knife height. This

requires the B65 full paper cutter control system and the AKS
kit.

Knife adjust

Manual adjustment using Automatic Knife Set system. This

requires the B65 full paper cutter control system and the AKS
kit.

24

THE MACHINE SET UP SCREENS

All microcut units must be told what type of machine they have been installed on. This routine only
needs to be done once, after the installation is physically completed. This will allow the computer to
learn about the machine, including how to drive the motor and how to count one for one with the
movement of the back gauge. At the first power on:
STEP 1: Power on, select Set Up

ORTap
for a normal
start up. Set Up will be forced if
it has not been done already.

Tap
to enter
the Set Up
Screen.

ORTap
to change
the language.

STEP 2: Select Machine Set Up

ORTap
to make
adjustments to the CLAMP and
KNIFE options.

Tap
to enter
the Machine Set Up
Routine.

ORTap
for file
management, touchscreen
calibration, and other options.

STEP 3: Define the machine

The Machine Definition Screen will appear. Use the

move the bubble over each line.
Tap

or

to

to select that line to make adjustments.

STEP 4: Name the machine

Position the bubble on the Cutter Brand line. Tap
.
Move the bubble to the desired cutter.
Tap

If you select a specific cutter the

parameters for that machine will transfer to
the screen (see the next several steps).

Check these for accuracy and

adjust as necessary.
STEP 5: Define the machine size
Position the bubble over any of the three Machine Size lines. Tap
Use

to enter the machine sizes. Use

or

to move up

and down the entry lines. When ALL the sizes are correct tap

The max rear size must be behind the preset value,

determined by the location of the Position Sensor.

25

STEP 6: Define the clutch type

Position the bubble over the Clutch Type line. Tap

or

Use
machine.
Tap

to move the bubble over the clutch type on your

STEP 7: Define the air control

Position the bubble over the Air Control line. Tap

or

Use
Tap

to move the bubble over Single or Dual Air Zone.

Dual Zone control implies that you have installed the optional Expansion Board or the B65
System. If you select Single then the output from the H3 drive and the Expansion/B65 board
will be the same. Otherwise the H3 will control Zone 1 while Zone 2 is controlled from the
Expansion or B65 board.

STEP 8: Define (if possible) the turns of the encoder per inch or cm of movement
Position the bubble over the Current
Pitch Value line. Tap
. Use
to enter the exact number of times
the shaft encoder rotates for each
inch or cm of gauge movement (see
Tap
.
the NOTE below).
NOTE: For many machines the gauge will move an exact number of cm or inches per rotation of the screw. The encoder
generally will turn exactly 1 or 2 turns for each rotation of the screw. So it is easy to calculate the turns of the encoder per
cm or inch of gauge motion. This is the value that allows the microcut computer to count one to one with the back gauge
motion. It is imperative that this be accurate to insure high precision. Entering this value directly will eliminate the need to
enter exact rear and front reference positions and will lead to a simpler and more accurate Set Up Routine calibration.

If the pitch is not known or it is an uneven number of turns, then enter the value as 0.
You will then be asked to move the gauge to rear and front reference positions later in this routine.

STEP 9: Define the screw type

Position the bubble over the Lead Screw Type line. Tap

or
Use
is on your machine.
Tap

to move the bubble over the type of lead screw that

STEP 10: State if there is a clamp encoder

Position the bubble over the Clamp Encoder line. Tap

or
Use
Installed line.

to move the bubble over the Installed or Not

Tap
.
The clamp encoder allows paper counting for the microfacts MIS
system. If you install this it will need to be calibrated See the section
titled The Clamp and Knife Set Up Screens.
26

STEP 11: Limit the maximum allowed operator speed input value
Position the bubble over the Maximum Back Gauge Speed line.
Tap
Use

.
to enter the maximum allowed speed for the back gauge (see

the NOTE below).

Tap

NOTE: While microcut allows for very high motor power and speed, there are mechanical limitations that the
machine itself presents. Trying to drive the gauge at very high speeds may draw excessive current (hurting
the motor) and create other problems such as damaging the machines transmission components. The PLUS
WS display has the option of setting an upper speed limit in the Machine Definition Screen at the beginning of
the Set Up Routine. In general machines using Acme screws should be limited to 8 inches per second (20 cm
per second) while ball screw machines may be able to achieve higher speeds. But a word of caution is
required here ball screws can whip at high speeds, especially when the gauge is near the limits and there is
more unsupported screw to whip. Do not set the maximum speed beyond the machines abilities. Some
machines will start to dynamically bind (as the lead screw pushes on the support bearings at either end of the
cutter or on the carriage nuts) before the speeds indicated above.
STEP 12: Define the maintenance schedule
Position the bubble over the Maintenance Schedule line. Tap
Position the bubble over each line.

Use
to enter the period to allow before the indicated maintenance
is required. Refer to the manufacturers specifications if possible (see
the NOTE below).
Tap
Tap

if you do not wish to track a specific line item.

to exit when everything is defined.

During operation when maintenance is due a yellow box will appear with the item indicated. If maintenance is
bypassed the system will add 10% to the value and wait until that new alarm is reached to warn the operator
again.
NOTE: If the manufacturers schedule is not available then you may wish to use the following values

Grease back gauge parts: Daily with light oil if Acme screw. 90 days if ball screw.
Grease outside flywheel and support bearing: Twice a year.
Check main motor V belts: Twice a year.
*
Certify all systems: Annually.
*
Check all connections: Annually.
*
Check machine level: Annually.
Change hydraulic oil and filter: After first 6 months and every two years thereafter.
Change gearbox oil: After first 6 months and every two years thereafter.
Change knife: 2500 cuts on single pull machines. 5000 cuts on two arm pull.
o For high speed steel knives.
o Carbide knives will last longer unless chipped not recommended for recycled stock.
**
Proofing tests: Every 6 months.

To be performed by a qualified trained technician.

**

These tests may require modification to the machine to perform. They are done to insure any redundant control is
operating properly. On the B65 control board built in software allows this testing to be done easily and quickly without any
modifications, tools, or training. Refer to the B65 Installation and Reference Manual if you have installed a B65 full paper
cutter control with your PLUS WS. For other systems contact a trained professional. The 6 month time period is based
upon European and British standards. Consult local requirements to the time frame you select.

27

STEP 13: Define the auto correction operation

Position the bubble over the Adaptive Settling line. Tap
Tap

to allow adaptive settling.

Tap

to disable this option.

If ON, then if the gauge oscillates around the target (a phenomenon

known as dither) the tolerances will open slightly to compensate and allow
the motor and brake to stabilize. The original tolerances will be reloaded
at the next drive command. If OFF, then the gauge will continue to
oscillate until the brake holds within the tolerances specified.
NOTE: If oscillation (dither) is a problem you may need a smaller pulley
on the motor or a larger pulley on the lead screw.
STEP 14: Decide if the operator needs a reminder to set the clamp pressure
Position the bubble over the Program a New Job Clamp Pressure Warning line. Tap
Tap

to show the warning each time a new job is started.

Tap
to skip the message. This only matters if you have a
proportional control valve on the clamp hydraulics to allow pressures to be
programmed from the display. An astute operator may not require the
warning. Others may find it beneficial.
STEP 15: Decide which target types will be available
Target types line Tap on any target type to place an X over the box or
not. Refer to the section titled Target Options for details.
Certain target types will not work on all machines. Refer to the section titled Target Options earlier in this
document for details of what each target type is. Enable or disable as appropriate. Tap
from the Machine Definition Screen.

to continue on

STEP 16: Define the motor drive direction

This step checks the motor drive direction.
Press

(Reverse) or

Once it moves far enough,

(Forward) icon and watch the gauge.

and

will appear.

if it was wrong.
Tap
if the drive direction was correct or tap
Depending upon your answer and the encoder counting direction (seen
by the computer) you may be directed to repeat this direction test.
STEP 17: Find the Position Sense to allow calibration
If everything is correct then

will appear. Tap

to start the calibration drive.

A
will appear on the screen and the
back gauge will drive to the back to
calibrate.

Tap

stop.
28

only for an emergency

STEP 18: If the encoder pitch was entered (see STEP 8 it was not 0):

Carefully move the gauge to a known value.

Use

or

or your hand wheel to position the gauge.

Use a tape measure to verify. BE ACCURATE!!!

Use

and

to enter this value.

If the computer calculates an error in the calibration value (table sizes) you will
be advised on adjustments to make. Otherwise, proceed to Step 19.

ORSTEP 18: If the encoder pitch was not entered (see STEP 8 it was 0):
Carefully move the gauge to the Maximum
entered earlier as requested on the screen.
Use

or

rear position you

or your hand wheel to position the gauge.

Use a tape measure to verify. BE ACCURATE!!!

Tap

when the gauge is in position.

The system will verify that the gauge is behind the preset value (located at the first shaft encoder zero index
behind the Position Sense). If this is not the case an error message will appear. The maximum rear must be
behind the preset value but not more than 20 encoder turns behind. If you have not made a measurement
error or if you can not move all the way back to the maximum rear then tap
to back up to the Machine
Configuration Screen to enter the correct maximum rear value (see STEP 5). Adjust the location of the
Position Sensor if necessary.
STEP 18 continued if the encoder pitch was not entered (see STEP 8 it was 0):

Move the gauge to the

False clamp position you entered earlier as

requested on the screen. Use

position the gauge.

or

or your hand wheel to

Use a tape measure to verify. BE ACCURATE!!!

Tap

when the gauge is in position.

NOTE: The numbers in the display will correspond with the numbers you entered in STEP 5. The numbers
above (45.000 and 3.000) are shown here for demonstration purposes only.
STEP 19:
Tap
for a
normal start up.

ORTap
to enter
the Set Up Routine.

ORTap
to
change the language.

Tap
to start. After calibration, move the gauge cautiously, making sure it is correctly calibrated and the
machine sizes do not allow the gauge to crash into either end of the cutter.

Note: If a small adjustment in the size is desired, tap

and select Calibrate Gauge.

29

THE CLAMP AND KNIFE SET UP SCREENS

The COLOR WS and PLUS WS display contains routines for special options for various machine
operations and monitoring. Special hardware is required for some of these. Your machine may not
be capable of everything that follows. Set up the operations of what is appropriate for you cutter via
the following routine:
STEP 1:

ORTap
for a normal
start up. Set Up will be
forced if it has not been done
already.
Tap
to enter the
Set Up Screen.

STEP 2:

ORTap
to
change the language.

ORTap
to enter the
Machine Set Up Routine.

Tap
to make
adjustments to the
CLAMP and KNIFE
options.

ORTap
for file
management, touchscreen
calibration, and other options.

STEP 3:

The Knife and Clamp Set Up Screen will appear. Use the
to move the bubble over each line. Tap
make adjustments.

or

to select that line to

Special equipment may be required for some of the features in the

table see below.
Clamp Pressure Set Up
Clamp Encoder Set Up
In Line Operation
Manual Hand Crank Knife
Auto Waste Removal Set Up

Auto Knife Set Installation

Proofing Tests

30

Select this to create a voltage output table based on % clamp pressure. This
requires that you have a proportional controlled clamp valve to adjust the clamp
pressure and either the Expansion or B65 board for interface.
Select this to allow the computer to calibrate the clamp encoder to the clamp
opening, with and without the clamp shoe installed. This requires the B65 full
paper cutter control system and a linear encoder attached to the clamp.
Enable to keep Auto Cycling active from one lift to the next for auto loading and
unloading systems. This requires the B65 full paper cutter control system.
Select this to lock on the knife clutch on for adjustment or manual movement.
This requires the B65 full paper cutter control system.
Select this to test operations, define the push out distance (to push stock from
the cutting stick), and to open, close, raise, or lower the front moveable table.
This requires the cutter to have a moveable front table and interface circuitry to
control it as well as the B65 full paper cutter control system.
This is used for machines that include motors and sensors on the knife linkage
to adjust the knife height. This requires the B65 full paper cutter control
system. Follow the on screen instructions to verify motor directions, sensor
operations, and calibration.
This is used to test hydraulic valves and other components on the machine that
are not testing during normal operation. This requires the B65 full paper cutter
control system. No special tools are required. Refer to pages in the B65 Paper
Cutter Control Installation Guide and Reference Manual for details.

THE UTILITIES SCREEN

The COLOR WS and PLUS WS display contains routines for file set up and management. Define
and control operations as appropriate for you cutter via the following routine:
STEP 1:

ORTap
for a normal
start up. Set Up will be forced if
it has not been done already.

ORTap
to
change the language.

Tap
to enter
the Set Up Screen.

STEP 2:
Tap
for file management,
touchscreen calibration, and
other options.

ORTap
to enter
the Machine Set Up
Routine.
ORTap
to make
adjustments to the CLAMP
and KNIFE options.

STEP 3:
The Utilities Screen will appear. Use the
bubble over each line.

or

to move the

Tap
to select that line for additional information or to make
adjustments.

Refer to the table below.

Error History
Maintenance History
Touchscreen Calibration
Update Software
Backup/restore/delete Job
Files
E-mail Set Up
Screensaver Selection
Enable Mouse Cursor
Exit to Desktop
Bar Code Reader Set Up
Remote Job Programming

Select this to review all fatal errors that have occurred dates of errors are
included.
Select this to review the dates of all maintenance that has been completed.
Select this for a 25 point touchscreen calibration. Follow the instructions on the
screen. The visual screen is a bit behind the touchscreen. The ideal calibration
for a tall operator may be different than a short operator.
Software versions before August 2013 update by placing a USB stick with the
new software into the slot after power on and by then pressing the REVIEW
icon. Newer software requires you enter this routine and follow the instructions
as they appear on the screen.
Use this routine to manage programmed jobs.
Use this to define e-mail addresses for microfacts reports. See the section
titled microfacts for more details.
Use this to select from a number of screen saver options.
If there is ever a problem with the touchscreen you can enable a USB mouse.
Connect the mouse to the USB slot before turning power on. At the Green Dot
Start Up screen drag the mouse to the far right (this will be blind the point is to
avoid activating the green dot) and press the right mouse button. You can also
turn the mouse on at this screen in case you want to go to the desktop for other
purposes (see next line).
This will allow you to exit to the Windows CE desktop for special purposes.
Use this to define a bar code reader to allow direct call up of remotely
programmed jobs via a bar code on the job ticket or printed item.
Enter this to get details on the requirements for programming a job off site.

31

ERROR MESSAGES
The control system is constantly checking to make sure that everything is correct during operation. If
anything appears to be wrong, a message will appear on the screen. These can be of three
different types
1. Conditional, just indicating operations as they progress.
2. Minor, where pressing any key will clear the screen and resume normal operation.
3. Major, where the power will have to be turned off and back on again, or repairs may be
necessary.
NOTE: Software changes occur that may add or remove messages. Changes in the listing may
occur. Error descriptions occur in the display to explain each one independently of the following.
Prompts generated by the display:
Entered value is too small!!!
This value cannot be zero!!
Cut stroke early!!
Job number already used!
Job number not found!!
Target is out of table range!!
Error in leadscrew values!
Error in machine sizes!!

Check keyed in value to move to

Cannot divide by 0
Wait longer before cutting
Choose a different number
Try another number
Trying to go too far back or forward
Inch, cm mm, sun pitches disagree, setup will be forced
Machine sizes are incorrect, setup will be forced

Refer to the following pages for more messages.

32

STATUS INDICATORS FROM THE H3 DRIVE COMPUTER

The computers track all operations of the machine and send reports to the display constantly.
Individual sensors are also monitored and displayed near the top of the screen. LEDs on the H3
Drive PCB allow you to perform additional evaluations. The following table lists error numbers sent
from the H3 to the display and their corresponding messages. The first number is in standard form
(Base 10). The number in parenthesis is in hexadecimal form (Base 16for computer counting).
JR and BASIC units display the hexadecimal form of the number as well as the message. The
PLUS WS unit shows the message followed by the standard (base 10) number.
Status
00
04
06
10 (0A)
15 (0F)

Drive computer conditions

Steady state, no errors
In preset drive routine
In factory reverse drive test
In knife change mode (special software required)
In calibrate gauge routine (momentary flash only)

96 (60)
97 (61)
98 (62)
99 (63)
100 (64)

Waiting for RAM download at power on

Waiting for preset drive (or factory test drive) at power on
AC power check (unused remnant of H1 drive)
In factory forward drive test
In knife change routine stage 2 (special software required)

128 (80)
129 (81)
130 (82)
131 (83)
132 (84)
133 (85)
134 (86)
135 (87)
138 (8A)
139 (8B)

Target lost
No motion seen (fatal error forced in preset or set up)
Data download time out error
Data download last byte not equal to #5Ah
Data download RB8 not set on last byte
Data download RB8 set before last byte
Data download version of 83h but with RB8 set
Too many over current errors during drive. The speed has been limited. Oil the
screw.
The heat sink on the drive box is too hot to continue driving.
The back gauge drive motor is too hot to continue driving.

181 (B5)
182 (B6)
183 (B7)
184 (B8)
185 (B9)
186 (BA)
187 (BB)
188 (BC)
189 (BD)
190 (BE)
191 (BF)
192 (C0)
193 (C1)

No motion at preset forward drive

Position sense error
No motion at preset reverse drive
Zero set missing after position sense
Reverse drive is forward
No motion at start up reverse test
Impaired drive at reverse test, lube
Forward drive is reverse
No motion at start up forward test
Impaired drive at forward test, lube
Duplicated data on last zero set position value lost
Too many counts without a zero set
UART time out errortoo long without communication from the display

NOTE: A 135, 138, or 139 error may occur if the machine needs to lubricated or the back gauge
speed is set too high. If lubrication is not performed or the speed reduced, another error is likely to
occur. On European machines with acme screws generally 6 to 8 inches per second (15 to 20 cm
per second) is a maximum speed. Anything beyond that will bind the screw and the bearings and
result in higher energy use without increased speed.

33

THE H3 BOARD

Revision 1 H3 boards:

See next pages for details on the LEDs and connectors.

34

Revision 2 H3 boards:

See next pages for details on the LEDs and connectors.

35

H3 LEDS

36

The following table defines the purpose of each LED. Refer to the connector table and cabling
diagrams as well.
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Definition when ON
Revision 1: Fuse 301 is OK (20 amp slow blow)
Revision 2: Not used
Revision 1: Full wave bridge (FWB301) is OK
Revision 2: Fuse 300 (20 amp slow blow or circuit breaker) and FWB351 OK (lights slowly at power
on)
Revision 1: Fuse 300 is OK (2 amp quick blow)
Revision 2: Not used
Revision 1: Voltage from TRAN302, FWB306, and F302 (5 amp) is OK
Revision 2: Fuse 301 (5 amp solder type) and 12VDC switching power supply are OK
+5 VDC from U307 is OK
UART send from H3 drive computer to Expansion computer is operating
UART send from Expansion computer to H3 drive computer is operating
The cut operation is being enabled
The air table is active
The brake is being energized to the not braking state
UART send from the H3 drive computer to the display is operating
UART send from the display to the H3 drive computer is operating
The current through the back gauge drive motor is not excessive
The clamp is in the full up position
The knife is in the full up positionnot active on this PCB, see B65 control PCB
The clamp shoe is in its holder rather than attached to the clamp (full forward drive is allowed)
The back gauge is in front of the rear position sensor
The hand wheel to manually position the back gauge is not pressed in
The A quadrature signal from the shaft encoder is active
The B quadrature signal from the shaft encoder is active
Flips each time the zero signal is received from the shaft encoder
The ZERO SET signal from the shaft encoder is active

NOTE: Revisions occur. LED functions and locations may vary. Terminal plugs and features may
be added. Refer to labels on the PC Board to verify options and functions.

37

H3 TERMINAL CONNECTION TABLE

The following table explains the function of the various connectors as well as the individual
connections of each. Notes are included as appropriate. The cable diagrams elsewhere may also
be beneficial.
Terminal

Pin

J300H

1, 2, 3

AC power into the H3 drivecheck SW300 for voltage range, center pin is earth (chassis)

J400H

1, 2, 3

Cable for back gauge drive motor, center pin is earth (chassis), also see J800H

J570H

1, 2, 3

Drive motor thermal couple connection to monitor heat and allow shut downs if > 85C

J601H

1
2
3
4
5
6

Computer ground to connect to B65 control PCB

Spare ground connection
Computer +12 VDC to connect to B65 control PCB
Spare +12 VDC connection
UART signal from H3 drive computer to Expansion computer
UART signal from Expansion computer to H3 drive computer

J800H

1
2
3
4
5
6
7
8

Ground for external relay coil connections (see Auxiliary Controls later in this manual)
+12 VDC for external relay coil connections (see Auxiliary Controls later in this manual)
Normally open contact for cut enable controlnot used
Normally open contact for cut enable controlnot used
Normally open contact for air enable controlsee B65 connector J400B
Normally open contact for air enable controlsee B65 connector J400B
Ground path to energize the back gauge motor brake
+12 VDC to energize the back gauge motor brake

J600H

1
2
3
4
5

Spare computer ground for the display power (possible shield connection)
Computer ground for the display power
Unregulated voltage (see LED 4 in previous table) for display power
UART signal from H3 drive computer to display computer
UART signal from display computer to H3 drive computer

J701H

1
2
3
4
5
6
7
8
9

Computer ground for the sensor power

+12 VDC for the sensor power
Ground connection from clamp sensor when clamp is full up
Computer ground for the sensor powernot used
+12 VDC for the sensor powernot used
Ground connection from knife sensor when knife is full upnot used
Computer ground for the sensor power
+12 VDC for the sensor power
Ground connection from clamp shoe sensor when clamp shoe is in its holder (not on the clamp)

J700H

1
2
3
4
5
6

Computer ground for the sensor power

+12 VDC for the sensor power
Ground connection from position sensor when the back gauge is in front of the sensor
Computer ground for the sensor power
+12 VDC for the sensor power
Ground connection from hand wheel sensor when the hand wheel is released

J702H

1
2
3
4
5
6
7

Computer ground for the encoder shield (optional)

Computer ground for the encoder power
+12 VDC for the encoder power
+5 VDC for the encoder power
A quadrature signal from the encoder (driven +12, driven +5, or open collector to ground OK)
B quadrature signal from the encoder (driven +12, driven +5, or open collector to ground OK)
ZERO SET signal from the encoder (driven +12, driven +5, or open collector to ground OK)

38

Purpose

PLUS WS COMPONENT MAP

WS Plus, 12 & 15 GUI panel components
Microcut
interface card

Coms connection
between interface
& CPU cards

Serial Coms & power

From H3 drive box

Display back
light connection
High voltage inverter
card for back light

GUI Celeron
CPU card

Power connection
between interface &
inverter cards
2 Ethernet sockets
for network etc

USB
connection
TFT display
connection plug

Touch screen
connection
cable
Touch screen
interface card

USB front
panel socket

5v & 12v feed

to CPU card
Touch screen card to
CPU card connection

DIP Switch
settings closeup

Display, Touch interface

& USB plug closeup

39

INSTALLATION BASICS FOR THE BACK GAUGE CONTROL SYSTEM

The microcut installation is basically mechanical. It involves mounting the display console; the H-drive
box; the DC motor to drive the back gauge; the shaft encoder to signal back gauge movement to the
computer; and four sensing switches to inform the computer of the machine status (clamp, knife, clamp
shoe, and position). All voltage cables are plug-in type. There is an optional input for a hand wheel
sense as well as outputs for air table control and cut disable.
The following text gives a conceptual approach toward the installation. Use this manual to learn what
each component must do. Mount each component in the fashion best suited to fulfill its purpose.
microcut is a retrofit system so every installation is unique. Install the components for function as well
as fit. The brackets are designed with extra holes and slots. They are easily modified, and can be
adapted for almost any requirement. Installation variables include the encoder sprockets and motor
pulley (Schneider cutters have a flat belt drive). If the lead screw diameter is known at the time of
shipment, the lead screw 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. Cut the sprocket in half to allow easier
installation.
Every display console is identical regardless of machine type. A setup 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.
Hints
1. Inspect the machine to insure all operations are correct BEFORE beginning the installation. Fix
problems now, not later.
2. The boxes are packed to facilitate the installation. The installation will be easier if the parts are not
mixed up. Box 1 contains the back gauge drive motor. Box 2 contains the motor drive, encoder,
sensors, and various brackets. Box 3 contains the encoder sprockets, display, mounting bracket,
and manual.
3. Lay out the entire installation before beginning, taking care to make sure that there are no
interferences, that the cables are long enough, and that there are safe routes to run the cables
4. Use the thinnest drive belt possible to minimize belt flex around the pulley. Use only one belt per
pulley. Multiple belts on any pulley will cause slower settling. The H-drive servo control unit works
best when the belt is fairly tight.
5. Do not over-tighten the back gauge. If there are nylon gliders supporting the back gauge keep
them loose to minimize lead screw flex.
6. Use the demonstration mode to allow the operator to learn the system while you are doing the
installation. To do this, plug in the cable between the display and the H3 drive box. Remove the
communication wire from the H3 to the display (J600H pin 4see H3 Terminal Connections later
in this manual). Wire the H-Drive to line power. Without communications from the H3 drive the
display will force demonstration mode when power is supplied.
NOTE: If you are installing an Expansion PCB, refer to the Expansion PCB section at the end of this
document.

40

SYSTEM OVERVIEW

Depending upon the customers needs the microcut installation may include several options:
Auxiliary outputs can be connected for air table and cut disable controls.
When installing a PLUS WS display, an Expansion PCB can be added for side loading, additional
I/O, and programmable clamp pressure control Refer to the connection inputs in information
earlier in this Owners Manual for details on wiring the Expansion board.
A full B65 clamp/cut control circuit can be added Refer to the B65 Installation Manual for details
on installing this full control system.
The display can be supplied in retrofit or OEM panel configuration as well (see the photo on the
cover).
Please feel free to contact your dealer, representative, or C&P Microsystems directly for more
information.

Notes:

41

BASIC LAYOUT

The H3 drive box acts as a junction for all of the parts you will be installing. Mount it in a central
location where the various cables can be safely routed. The methods you use to mount each item
will depend upon the machine, the additional systems you may require, the physical environment,
and the operators preferences.
The power and main motor cables should be run away from the other cables (the other cables should
avoid high power wiring).

Notes:

42

OPTIONAL AUXILIARY CONTROLS

Auxiliary control outputs may be desired dependent upon the machine and the operators
requirements. These may include air table control or cut disable (to prevent knife operation while the
gauge is in motion). There are several options for interfacing these controls. Please note:
1. The above control outputs do not conform to and are not intended to be used as safety devices.
All outside circuits must have the integrity to operate on their own.
2. A spike suppressor must exist across the added relay coil to prevent damage to the H-Drive
console relay drivers. For DC coils a snubber diode should be added (1N4002 or better). The
striped end of the diode goes towards the + side of the relay coil. For AC coils an appropriate
RC circuit should be added (100 to 150 ohms with a several uF cap). Failure to install or
incorrect installation of a spike suppressor will cause failure of the reed relay (K800 or K801)
and subsequent failure in the branch control circuit.
3. Until power on is recognized from the display the power up mode will be forced wherein the air
table and cut disable are off. The cut disable is off to allow circuit verification during the start
up procedures.
Additional controls can also be added. Refer to Optional Expansion section later in this manual.

Notes:

43

SAMPLE INSTALLATION DIAGRAM

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. Some machines interlock with the drive motor. The knife and clamp will not
operate if the motor is removed. In this case mount the motor on a cross leg or other convenient
location and make sure if the pulley turns it is properly guarded.

Notes:

44

RECOMMENDED TOOL LIST

You may want to adapt this list. Substitute metric drills and taps if you wish to supply your own
hardware. The procedures are listed in their order of execution, as well as the tools required to
proceed. An installation will be faster if all tasks in a given section are completed before starting the
next. If possible, lay out all of the components on the table to help visualize the entire installation.
DETERMINE ALL DRILLING LOCATIONSMark all holes that will be drilled to complete mounting
of ALL components, including holes to secure tie strap brackets, at the same time.
Slide T square with level
Pencil
Punch
DRILL ALL HOLESProtect the machine from drill shavings, then drill all holes necessary to mount
all components. Use the pilot drill for all holes before increasing drill size to save time. Be careful not
to drill any hole too large as the drill size is increased.
Paper and rags to cover machine surfaces
Pilot, #7, 5/16" high speed drill bits
Electric hand drill
Extension cord
TAP ALL HOLESComplete all threads for all of the components.
6-32, 1/4-20, 3/8-16 taps
Tap handle (ratchet type is convenient)
Tapping fluid
CLEAN THE MACHINEClean the machine to prevent future damage.
Brush
Rags
Magnet
BOLT AND SECURE ALL PARTS TO THE MACHINE
7/16, , 9/16 inch wrenches and sockets
Phillips screw driver
Hacksaw and file to saw off excess threaded rod and modify guards
ROUTE THE CABLESWire all components. Use tie straps to secure the wiring.
Side cut pliers
Wire strippers
Screwdrivers

45

THE MECHANICAL INSTALLATION

Display Console The display console is the operators interface with the system.
1. The display console should mount on the front of the cutter near the operator. The display
rod can mount to the left or the right. This is secured by the Panavise mounting bracket.
2. Mount this bracket to the machine based upon operator preference.

NOTE: The retrofit display is supplied in a small plastic console

to facilitate large variations in the mounting. C&P Microsystems
does offer an OEM panel for some cutters at an additional cost.
Please feel free to contact your dealer, representative, or C&P
Microsystems directly for more information.

46

Shaft Encoder The shaft encoder sends pulses to the drive to indicate back gauge position.
1. Use the shaft encoder mounting brackets supplied to mount the shaft encoder near the lead
screw.
2. Install a sprocket on the encoder shaft that will allow it to turn at least two, but not more than
four turns for one inch (25 mm) of back gauge movement.
3. Clamp the sprocket to the lead screw with the 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. Insure the clamp does not interfere with the chain.
4. 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. The chain can be split and snapped back
together to allow for any required length.

Rear mounting option

Front mounting option

47

PROXIMITY SENSORS
The sensors allow the system to know what the cutter is doing. Each sensor cable is labeled and
must be installed according to its designation. The open collector type sensors are interchangeable,
each containing a normally open and a normally closed contact (selected by the wiring method at the
PCB connector). Use any combination of brackets and hardware to install each sensor securely to
the machine according to the following criteria:
NOTE: The electrical purpose of each sensor is supplied in case the sensor is replaced with a
different type of a switch. Refer to the labeling at the drive console for voltages and sensor
inputs. Wiring can be cut to length as required. The optional hand wheel sense supplies ground
to allow gauge drive. This is jumpered when not used. The cable wiring colors are blue =
ground, brown = +, black = normally open, and white = normally closed.

Position Sensor supplies ground when the gauge is not near the rear of the table.
1. Move the back gauge to its rearmost position.
2. Mount the position sense so that it will be tripped by the gauge one or two inches (25 to 50
mm) before the back gauge reaches the maximum mechanical rear position.
3. Do not mount the position sensor so far forward that the back gauge may move behind it and
allow the sensor to become "untripped" as the gauge is moved to the extreme rear.
4. Do not mount the rear position sensor more than ten full encoder revolutions from the
mechanical rear of the cutter.
5. Use the supplied trip plate if the cutter is heavily painted or if the surface to be sensed is not
flat.

Above table

48

Under table
Below table

Clamp Up Sensor supplies ground when the clamp is full up.

1. Mount this sensor so that it is tripped only when the clamp is in its full up position. Horizontal
mounting of the sensor barrel prevents complications that can arise due to hydraulic sag.
2. Use the supplied trip plate if the cutter is heavily painted or if the surface to be sensed is not
flat.

49

Cut Sensor supplies ground when the knife is up.

1. 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.
2. This sensor must be tripped for at least 1/4 second during the knife cycle to register a cut.
3. This sensor must only be tripped once per knife stroke. Beware the double-tripping effect
that holes, lips, and bolt heads can cause.

50

Clamp Shoe Sensor supplies ground when the clamp shoe is in the holder.
1. Mount this sensor so that it is tripped when the clamp shoe (false clamp or sole plate) is
resting in its holder. If there is no clamp shoe holder, use the multi-angled brackets supplied
to create one.

Hand Wheel Sensor supplies ground when the hand wheel is released.

This is normally a

jumper wire on the J700H terminal (from pin 4 to pin 6). If your cutter has a retractable hand
wheel with a switch, wire this switch into J700H to perform the proper function. You may need to
change the contacts on the switch.

51

DC Drive Motor The motor turns the lead screw.

1. Use the brackets and 9 by 12 inch plate as needed to mount the motor so that it lines up with
the existing lead screw drive pulley. In many cases the same belt can be used for the new
motor as was used for the original equipment drive. The motor mounting method must
isolate the original drive system to avoid contention between the two.
2. If microcut is ordered for a Schneider cutter a one inch wide cog belt pulley will be included
with the kit to drive with the original flat belt. If the original motor is removed make sure wires
are labeled and taped.
3. On some cutters the brake will have to be disabled and the drive clutch enabled to allow
proper operation.
NOTE: The brake on the motor will prevent the back gauge from moving. Install the encoder and any other
parts that may require manually moving the machine (to make adjustments) before you install the drive motor!!!

Polar

Wohlenberg

52

Harris

Lawson

H3 Drive Box

The H3 drive box drives the gauge motor and acts as a junction box for the

wiring.
1. Use four bolts with flat and lock washers to install this in a central location. Make sure the
cables will reach all of the components. Do not mount this box on a moving panel. The AC
and motor plugs should exit the top. They can be routed down the back of the drive box. It is
best to plug them into the box and route them this way as you install the box. If you know
what voltage you will be supplying the selector switch in the box can be set at this time.

53

WIRING AND POWER

Be sure that the original equipment back gauge motor cannot drive the lead screw. Be certain that the
original equipment back gauge brake will not energize during motor drive. If a clutch needs to be locked
on (electrically or mechanically) to allow the microcut motor to drive, do this now. If any modifications
are made completely insulate any bare wires, label all wires, and pack all original parts that were
removed. 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 wiring and motor should
be refitted on the NOTES page at the end of this document. Check the machine for operation in case
any of the above modifications may have affected operation.
Refer to the Basic Layout page earlier in this manual. Choose cable paths that avoid all moving parts
for all machine operations. Secure all cables appropriately. The power and main motor cables should
be run away from the other cables (the other cables should avoid high power wiring).
Wire the proximity sensors to the plugs according to function on the color dots on the plugs. The cables
can be cut to convenient lengths or the excess can be tied out of the way. The proximity sensor cables
are split into two groupsone for housing mounted sensors and one for the table mounted sensors.
This facilitates easier moving of the machine in the future in case the table must be removed. The table
connector contains the option for a hand wheel sense input if the cutter has such a switch. If this is to
be connected remove the jumper and wire according to the Wiring Diagram page earlier in this manual.
Plug the cable supplied with the encoder into the drive box. Route this to the encoder and plug it in.
The 7 pin connector for the encoder can be wired for either 5VDC or 12VDC encoder operation. This is
done at the factory and should not be changed unless a different encoder is supplied at a later date.
Refer to the silkscreen on the PCB as well as the Basic Layout page earlier in this manual for details.
The motor connects to two different cables. The 3 prong female line cord plug supplies DC drive power
from the drive box to the three pin connector at the motor. The 8 pin connector at the drive box contains
a cable that attaches to the motors 12VDC brake. The motors direction is determined during the set up
routine (see the Owners Manual). The additional connections on the 8 pin plug for the brake are for
additional machine controlsee the Auxiliary Controls page earlier in this manual.
Connect the display console to the drive box with the supplied cable. Route the cable and plug it into
the drive box.
If the Expansion board was included as a part of this installation, connect sensors and outputs to that
board as required.
Supplied power is to be 110/22010% VAC, 50/60 Hz. There may be a voltage selector switch in the
drive box (Revision A1.x PCBs). Remove the cover and make sure the switch is set correctly for the
voltage you will be supplying. If you are removing the plug to hard wire the cord, the center of the plug
(yellow wire with green tracer) is the earth connection. The other two lines are for the power. Check the
plug to make sure this is correct. Plug the cable into the drive box.

54

SPECIAL NOTES
The microcut control system is available with different displays for different needs. The JR and
BASIC units require the set up routine only. The PLUS WS has several configurations that can be
defined. Refer to the special notes in various sections of the Owners Manual for details.
Jumper JP700 on the H3 Drive board can be used to select the motor voltage. You can choose
either the 90 or the 180VDC option. The motor must be a permanent magnet type. It should be
adequately sized to avoid stalling or overheating. The brake output supplied from the H3 Drive Box
is low power (1 amp max) 12VDC. The brake is not mandatory for operation but may help to
stabilize the screw.
Jumper JP701 on the H3 Drive board can be used to select hard or soft braking. It is recommended
that the soft option be selected for ball screw drives while Acme screws generally work well with hard
braking. The system allows you to set the % of braking force to be used as well.
A potentiometer exists on the H3 Drive board
to set the maximum current allowed through
the back gauge drive motor. If this is set too
low then the acceleration may be limited and
the obtainable speed may be decreased. If it
is set too high, then too much current may be
allowed through the motor and the life of the
motor may be reduced. A table silkscreened
next to the potentiometer offers guidance on
the setting. Generally DC motors require a
surge of current to get moving. Generally, in
the operation of a paper cutter, the motor has
long cooling periods between moves. So,
generally, this potentiometer is set a bit higher
than the motors specified (constant) current value. The major concern is to not overheat the motor.
C&P Microsystems offers an input on the H3 board to monitor the motor temperature (J570H).
Please contact us for further information.
While microcut allows for very high motor power and speed, there are mechanical limitations that the
machine itself presents. Trying to drive the gauge at very high speeds may draw excessive current
and create other problems such as damaging the machines transmission components. The PLUS
WS display has the option of setting an upper speed limit in the Machine Definition Screen at the
beginning of the Set Up Routine. In general machines using Acme screws should be limited to 8
inches per second (20 cm per second) while ball screw machines may be able to achieve higher
speeds. But a word of caution is required here ball screws can whip at high speeds, especially
when the gauge is near the limits and there is more unsupported screw to whip. Do not set the
maximum speed beyond the machines abilities. Some machines will start to dynamically bind (as
the lead screw pushes on the support bearings at either end of the cutter or on the carriage nuts)
before the speeds indicated above.

55

FINAL CHECK
Insure that
The machine is fully cleaned from the installation.
All parts are securely mounted to the machine.
The motor pulley is secure.
The motor drive belt is correctly aligned and fairly tight.
The encoder chain is aligned and snug.
The encoder sprocket clamp does not interfere with the chain or machine.
All cables are secure and clear of all machine operations.
All machine operations (cutting, clamping, etc.) are functioning properly.
All hazard points (pinch, crush, etc.) must be fully guarded.
Review the machine for any areas that could create hazards such as pinch points or exposed parts.
Guard as appropriate. Remember 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 alteration to the knife or clamp safeties, circuits,
or operation, or any installation technique that 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 parts and assemblies are added to the machine. 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. Any nip, draw-in, crush, or shearing hazard
must be evaluated and eliminated.
Use the NOTES pages throughout this manual to document all changes that were made to the
machine during the installation as well as steps to perform to return to the original operation.
Show the operator the installation, making sure he is comfortable with all mounting locations.
microcut is designed for all machines. When shipped the unit has no idea what type of machine it is
on. The Set Up Routine allows microcut to understand the machine it has been installed on. This
must be completed to allow correct operation. Until then motor and counting direction may be wrong
and the machine sizes may be wrong. Serious damage may be inflicted on the machine while this is
the case. Do not operate microcut until the Set Up Routine has been completed. It is a good idea
to go through this routine with the operator so that he is familiar with the approach and can select the
correct machine sizes and operating parameters. Refer elsewhere in this Owners Manual for details
on the Set Up Routine.

56

OPTIONAL EXPANSION BOARD CONTROL PACKAGE

The microcut control system can be augmented with an Expansion PCB. This is usually mounted
directly above the H3 Drive PCB. The Expansion PCB has a variety of inputs and outputs that
include:
Additional output control for
o High pressure clamp enable.
o Auto cycle operation.
o Air table (same as the H3 output).
o Open 1. Defaults to Load enable.
o Open 2. Defaults to Cut Optimization enabled.
o Open 3. Defaults to Auto Trim Removal Table Drive enabled.
o Air motor.
o Auto cycle enable.
NOTE: The open outputs can be used for operations such as load enable, cut optimization, or trim
removal.
Additional inputs for
o Covers on.
o Shear bolt 1.
o Shear bolt 2 (for double arm pull machines).
o Foot treadle.
o Auto cycling circuit powered input.
o E-Stop for complex machine grouping.
o Air paddle for flipping air on off without affecting program (requires special parts).
o Auto trim table full in (requires special parts and construction).
o Oil filter (requires special parts).
Side loading monitoring and options.
Programmable clamp pressure.

All inputs and outputs have associated LEDs for diagnostic purposes. Refer to the next pages for
details.
Input errors will be displayed in the upper left corner of the display or via red STOP SIGN like boxes
in the middle of the display.
Since the Expansion PCB blocks the H3 PCB when mounted above it, a ribbon cable sends the H3
LED signals to the Expansion PCB.

NOTE: The PLUS WS system can also be interfaced to the C&P

Microsystems B65 full cutter control package.
Refer to
documentation specifically for the B65 control system for details.

57

THE EXPANSION BOARD

Refer to the labels on the PCB. Green on = true, Red on = false.

See next pages for details on the LEDs and connectors.

58

EXPANSION LED DEFINITION TABLE

The following table defines the purpose of each LED. Refer to the connector table and cabling
diagrams as well.
Data In
Data Out
Current OK
B
A
Zero
Hand Wheel In
At Rear
Shoe On
Knife Down
Clamp Down
Mechanical
Load Clear
Optical Load
Clear
Drop Gauge Up
Brake Off
Air Off
No Cut
Oil Filter OK
Trim Table In
Air Paddle
Pushed
OK for Actions
Auto Cycle
Powered
Foot Treadle
Down
Overload 2 OK
Overload 1 OK
Guards OK
Auto Enable
Air Motor
Open 3
Open 2
Open 1
Air Table
Auto Operate
Clamp enable
Data from H3
Data to H3

Definition when ON
On if the outside source is communicating to the Expansion CPU (custom software
required)
On if the Expansion computer is sending data to the outside source
The back gauge drive motor is not requiring excessive current
The lead screw encoder B signal is active
The lead screw encoder A signal is active
This flips each time a zero indicator is seen from the lead screw encoder
On (red) when the hand wheel is pushed in and prevents back gauge drive or knife
operation
On if the Position sensor at the back of the machine is being tripped by the back gauge
On if the clamp shoe is attached to the clamp allowing reduced forward drive
On (red) if the knife is down preventing other operations until the stroke is completed
On (red) if the clamp is down preventing normal forward back gauge drive
On if the mechanical loading paddle is clear of the machine (used for side loading
operations to insure that the back gauge does not run into the loading equipment)
On if the optical sense indicates that there is nothing in the side loading throat (used for
side loading operations to insure the back gauge does not jam stock into the housing)
On if the retractable side gauge plate is not down (used for side loading applications)
On if the back gauge brake is off (energized to the off state) to allow manual adjustment
On (red) if the air table is off
On (red) if the knife is disabled (moving, not at target, or other cause)
On when the oil filter is OK or the operator will be reminded occasionally
In if the trim removal table is in the full in position
On if the air paddle is pushed to flip the air table status
NOTE: This will not change the programmed status in AUTO operation
On if all E-Stops are in the OK TO RUN position
On if there is power to operate the auto cycle (cut or clamp) circuits
NOTE: Additional circuits are required for Auto Cycle Operation
On if the foot treadle is pressed down
On if the shear bolt 2 (over load on second knife pull down arm) is OK
On if the shear bolt 1 (over load on knife pull down arm) is OK
On if all guards and covers (that are interlocked) are in place to allow machine operation
On if Auto Cycle Enable is enabled (sets up circuit for Auto Cycle Operate below)
On if the air motor is enabled
On if Open 3 is enabled (defaults to auto trim waster removal table enabled)
On if Open 2 is enabled (defaults to cut optimization enabled)
On if Open 1 is enabled (defaults to load enabled)
On if the air table is enabled
On if Auto Cycle Operate is enabled (requires Auto Knife Enabled above)
On if the high pressure clamp is enabled
On if the H3 Drive computer is communicating to the Expansion computer
On if the Expansion computer is communicating to the H3 Drive computer

NOTE: Revisions occur. LED functions and locations may vary. Terminal plugs and features may
be added. Refer to labels on the PC Board to verify options and functions.

59

EXPANSION TERMINAL CONNECTION TABLE

The following table explains the function of the various connectors as well as the individual
connections of each. Notes are included as appropriate. The cable diagrams elsewhere may also
be beneficial.
Terminal
J100E

Pin
1
2
3
4
5
6

J200E
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

60

Purpose
Connects power and communications between the H3 drive unit and the B65 control board.
0V supplied from H3 drive unit
Spare 0V supplied from H3 drive unit
+12VDC supplied from H3 drive unit
Spare +12VDC supplied from H3 drive unit
Communications to Expansion CPU from H3 drive unit
Communications from Expansion CPU to H3 drive unit
Connects various external sensors
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when all interlocked covers are on
The main motor will shut off and all operations disabled if 4 is not at GND.
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when shear bolt 1 is OK
The knife will not operate if 8 is not at GND.
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when shear bolt 2 is OK (two arm pull machines)
The knife will not operate if 12 is not at 0V.
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when the foot treadle is not full up
0V at 16 allows the clamp operation and forces a clamp down status at the H3 drive unit.
There are several other subtle functions involved as well.
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when cut is OK with the clamp
This involves special wiring for high pressure clamping buttons. Refer to the cabling
diagrams elsewhere.
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when all E-Stop switches are in the OK TO RUN position
All operations will be disabled, but the main motor will not shut off, if there is no 0V to 24.
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when air paddle switch is pressed (to flip the air table)
Each time 0V is supplied to 28 the computer will flip the status of the air table.
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when trim removal table is full in
Normal back gauge drive will be disabled unless 32 is supplied with a 0V path. Refer to
J400B pins 13 and 14. Trim removal is for COLOR units only and, when programmed,

Terminal

Pin

33
34
35
36

J201E
1
2
3
4
5
6
7
8
9
10
11
12

J350E
1
2
3
4
5
J400E
1
2

3,4
5,6
7,8
9,10
11,12
13,14
15,16
17,18

Purpose
allows the clamp to be lowered, then the trim table extended, then the cut can be made,
followed by a small push out to clear the trim, before the table is returned (supplying the 0V
to 32).
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when the oil filter is OK
If 36 does not have a 0V then it is assumed that the oil filter is plugged. Operation can be
performed, but the operator will be interrupted occasionally with a warning message.
Connects to the side (rear) loading sensors. A failure to supply 0V at any of the sense
inputs will prevent back gauge drive.
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when the drop gauge is full up
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when the optical loading sense is clear
0V connection to supply a cable shield
+12VDC to supply power to the sensor
0V connection to supply the sensor and return signal
0V return path for when paddle to load the stock is clear of the table
Input 12 (paddle) can be used to advance the back gauge after the load is complete. The
other sensors on this connector are for stopping gauge drive only.
Clamp pressure control and RS-232 for additional expansion. A 0 to 10VDC input control
valve is required for clamp pressure control. 24VDC will be needed for the valve from a
different power source.
0V for 0 to 10VDC output to control clamp pressure
0 to 10 VDC output to control clamp pressure
0V reference for communication expansion
RS-232 output signal to outside source
RS-232 input signal from outside source
Additional control outputs from the Expansion computer. These outputs connect to minimal
power reed relays. They are generally used as inputs to a PLC or to control the coils of
relays whose contacts can be used for high power operation.
0V connection for the relay controls
+12VDC connection for the relay controls
The +12VDC supply is rated for 60 watts. This supplies all of the computers, the display,
and various sensors. Care should be taken to not over load the supply. The +24VDC
supply may be used to control the outputs as well.
Output contacts that close when it is OK to high pressure clamp
Output contacts that close when auto cycle is OK to operate (external circuitry required)
Output contacts that close when the air table is on
Output contacts that close when to be defined (old loading device is to be enabled)
Output contacts that close whento be defined
Output contacts that close whento be defined (old trim removal table is to be activated)
Output contacts that close when the air motor is on
Output contacts that close when auto cycle is enabled (external circuitry required)

61

SPECIFICATIONS/LIMITATIONS
Power input: 110/22010% VAC, 50/60 Hz, 1KVA. Voltage based on position of SW300 on H3 PCB.
Motor output: 0 to 90 VDC (PWM controlled, peak voltage based upon DC bus created from AC input)
Motor type:
90VDC permanent magnet type up to 1 HP
Frame size can vary based upon mounting requirements
RPM can vary based upon full speed requirements
Power can vary based upon load requirements
Sensors:
Normally open (clamp up, clamp shoe) open collector type at 12VDC
Normally closed (position, cut) open collector type at 12VDC
Encoder:
Incremental type
5VDC or 12VDC input dependent upon termination at H3 drive box
500 windows with A and B outputs
Zero pulse (either normally high or normally low acceptable, gated or not)
Open collector or driven is acceptable.
Auxiliary I/O: Refer to details elsewhere in this manual
Display: Unregulated input from 12 to 28VDC with RS-232 interface from/to drive box
Climatic considerations:
Operation (weather protected control rooms or equipment rooms not fully air conditioned)
Temperature per Class 3K3 +5C to +40C.
3
3
Relative humidity per Class 3K3 5% to 85%, 1g/m to 25g/m .
No condensation or formation of ice.
Air pressure per Class 3K3 86 kPa to 106 kPa.
Storage
Temperature per Class 1K4 -25C to +55C.
3
3
Relative humidity per Class 1K3 5% to 95%, 1g/m to 29g/m .
Air pressure per Class 1K4 86 kPa to 106 kPa.
Transportation
Temperature per Class 2K3 -25C to +70C.
3
Relative humidity per Class 2K3 to 95%, to 60g/m .
Maximum RH based on
Unit slowly increases temperature by 40C.
Unit moves directly from temperatures between -25C and 30C.
Unit moves directly from temperatures between 70C and 15C.
Brief light condensation is acceptable.
Air pressure per Class 2K370 kPa to 106 kPa.

62

63

NOTES
17 July 2012 Changed format moving Installation Section to back instead of the very front.
30 September 2013 Conversion to a full Reference Manual.
25 February 2014 Modified for current updates.
10 March 2014 Added Color WS edits for multi model use

64