SERVICE MANUAL

V 1.01
 AeroCut Prime/ One/ Velocity SERVICE MANUAL

Contents

1. Installation................................................................................... 4
1- (1)Installation ............................................................................................ 4
1- (2)Installing options................................................................................... 7
2. General instruction................................................................... 12
3. Touch panel operation.............................................................. 16
3- (1) SERVICE MENU ............................................................................... 16
3- (2) MANUAL OPERATION Screen ......................................................... 18
3- (3) SPEED Screen .................................................................................. 20
3- (4) FEED Operation Screen.................................................................... 20
3- (5) SLITTER Operation Screen............................................................... 21
3- (6) INPUT DATA CHECK Screen ............................................................ 21
3- (7) LANGUAGE Screen .......................................................................... 26
3- (8) MAINTENANCE Screen .................................................................... 27
4. Paper jam .................................................................................. 29
5. Replacement of parts ............................................................... 31
5- (1) Slitter Unit.......................................................................................... 31
5- (2) Slitter head ........................................................................................ 33
5- (3) Guillotine Unit .................................................................................... 37
5- (4) X-perforator blade.............................................................................. 38
5- (5) Y-perforator blade .............................................................................. 40
5- (6) Feed belt Unit .................................................................................... 41
6. Adjustment ................................................................................ 42
6- (1) Feed settings..................................................................................... 42
6- (2) Cut mark sensor ................................................................................ 50
6- (3) PCB setting (AeroCut Prime)............................................................. 51
6- (4) PCB setting (AeroCut One/Velocity) .................................................. 53
6- (5) Accuracy adjustment ......................................................................... 55
7. How to make layout .................................................................. 56
7- (1) Prime general template ..................................................................... 56
7- (2) One general template ........................................................................ 57
7- (3) General template(inch) ...................................................................... 58
7- (4) How to use barcode........................................................................... 59
8. Electricity related...................................................................... 67
8- (1) Equipment, Electric circuit, and parts ................................................ 67
8- (2) Board Details ..................................................................................... 70
8- (3) Input/Output LED Details................................................................... 72
8- (4) Tap Voltage Details ............................................................................ 75

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

8- (5) Wiring Details .................................................................................... 76

8- (6) Servo motor driver setting ................................................................. 78
8- (7) Initial Setting of Touch Panel ............................................................. 81
9. Program update ........................................................................ 82
9- (1) Software install .................................................................................. 82
9- (2) Touch panel ....................................................................................... 89
9- (3) CPU board......................................................................................... 93
10. Cleaning & greasing ............................................................... 99
11. Recommended replacement parts ...................................... 100
12. Troubleshooting.................................................................... 101

Record of change
No. Date Contents of change Expected date
to change
5
4
3
2
1 2017/02/20 Slitter adjustment. (Page 36) 2017/02
PCB setting. (Page 51,53)

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

1. Installation

1- (1)Installation

(a) Fixing screw

The fixing screws shown on below images must be removed before use.

Note.
Do not forget to remove screws
before use, otherwise machine
will be broken.

(b) Caster
Please be sure to lock a caster brake.

Unlock

Lock

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

(c) Feed table

Hex key

Feed table

M4x8

(d) Stacker and Waste box

① Place the Waste box under the Chute.

Chute

Waste box

② Open the stacker and set the stays in the indentation of the back of the stacker at an
appropriate angle to allow smooth paper ejection.
③ Adjust the large paper guide according to the paper size.

Paper Guide (Large)

Indentation

Stack

Stay

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

④ Hang the business card stacker to the Stacker panel.

⑤ Find the V- notch to see where to put the business card partition.
⑥ When it is not used, it may be hooked to the upper holes in the stacker panel.

Upper holes

Stacker panel

V-notch

⑦ Change the settings of the stacker according to the cut pattern.

Business card Post card

Business card partition

Card stacker

Card stacker
Stacker end Stacker end

(e) Electric-power

ON

OFF
Electric power cord

Power switch

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

1- (2)Installing options
(a) Y-perforator
① Remove the delivery guide.

Note.
In case Perforator unit is not set in the machine, please attach the delivery guide
instead in order to avoid paper jam.

② Attach Y-Perforator unit. Knob

・Be sure to hold the perforator with
both hands and attach it as shown in
the figure.

・Fasten knobs to fix the position of

the unit.

・ Put the connectors into sockets

according to the numbers shown.
（Prime）
Connector

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

③ Double tap on bottom left corner of MANUAL/SPEED screen.

Double-Click

Double-Click

④ Activate JUMP PERFORATION（Prime）

Activate PERFORATION（One/Velocity）

⑤ Reboot the machine before use.

(b) X-perforator
① Remove the delivery guide.
Note.
In case Perforator unit is not set in the machine, please attach the delivery guide
instead in order to avoid paper jam.

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

② Attach X-Perforator unit.

・Upper part
Ensure to hold the perforator with both
hands and attach it with pushing it
against the counter-operation side as
shown in the figure.

・Don’t forget to connect cables.

Connector

③ Adjust the width of unit guide if necessary.

・The width of unit guide can be adjusted by moving guide which is attached paper
ejection side from side to side.

X-perforator unit
guide

Feed
Paper ejection side Paper feeding side

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

④ Double tap on bottom left corner of MANUAL/SPEED screen.

Double-Click

Double-Click

⑤ Activate CROSS PERFORATION

⑥ Reboot the machine before use.

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

(c) Barcode reader

① Replace the Origin Sensor Cover with the Origin Sensor Cover for the Barcode
Reading Kit, and attach the Barcode Reading Kit to the machine.
② Fix the Barcode Reading Kit so that a hole on left side will be placed towards the
top.
③ Position should be as below picture.

Origin sensor cover

Hole on left side

Barcode reading kit

Origin sensor cover for barcode reading kit

④ Connect the cables according to the red line as shown on below picture.
⑤ The Barcode Reading Kit should be connected to CN19 on the CPU board.

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2. General instruction

(a) Caution

Creaser Guillotine blades

Perforator blade

Timing belts

High voltage

Slitter blades

Timing belts

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(b) Necessary tools

・C-clip ring pliers ・Maintenance kit

Pipe
(For slitters) Program update tool

To replace slitter blades

To replace slitter blades

Roller remover

To cleaning roller

(c) Factory setting

Factory setting sheet is attached inside of
the front cover.

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(d) Remove covers

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(e) Names of parts

Margin Creaser
slitter Guillotine(Cutter)
Gutter motor Stop sensor
slitter Gutter slitter unit
motor Y-perforator
Margin slitter unit
X-perforator
Guillotine
Feed motor
motor
Fan motor (Suction)
Timing
belt

Feed belts
Conveyor
connector Feed sensor

Fan motor
Transformer (Blow)
PCB (I/O board) Feed table
PCB (CPU board)
Touch panel
Servo amplifier
DC power supply Adjuster
Feed table motor
Power switch
Micro switch
(Feed table lower limit) Inlet

X-perfo motor
Y-perfo head
(Solenoid)

Sponge
roller
Cover sensor
Carrying
roller

Crease
Fan motor motor
(Side Blow)

Main
motor

Timing belt

Cover sensor
Waste chute

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3. Touch panel operation

3- (1) SERVICE MENU

AeroCut Prime AeroCut One / Velocity

Double click at the top left corner. Double click at the top right corner.

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

Double click at the top left corner. Double click at the top left corner.

Enter the service password. Enter the service password.

Program Vesion
TP-V stands for Version of the Touch Panel image.
CPU-V stands for Version of the CPU board program.

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

3- (2) MANUAL OPERATION Screen

AeroCut Prime

AeroCut One / Velocity

① Carrying roller will rotate.

② Carrying roller will rotate. (Continuous)
③ The speed of Carrying roller can be adjusted to two levels (SLOW or FAST).
④ Carrying rollers will rotate at input length. [mm]
⑤ Enter the dimension of Fixed feed.
⑥ X-Perfo blade will move toward far side from an operator.
⑦ X-Perfo blade will move toward near side from an operator.
⑧ X-Perfo blade will move to specified point .[mm]
⑨ Input moving distance of X-Perfo blade.[mm]
⑩ Guillotine will move once.
⑪ Crease will move upper limit.
⑫ Crease will move lower limit.
⑬ Go to SPEED screen.
⑭ X-Perfo blade will move to initial position.
⑮ Go to FEED Operation Screen.
⑯ Go to SLITTER Operation Screen.
⑰ Go to INPUT DATA CHECK screen.

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⑱ SV OFF: the state where the servo motor does not respond to any orders.
SV ON: the state where the servo motor responds to all orders.
⑲ Reset the counter for servo movement to zero.
⑳ Counter for servo movement.
㉑ Switch ON/OFF of each Y-Perfo
㉒ Check operation of X-Perfo. Count times of operation.
㉓ Check operation of jump function of Y-Perfo. Count times of jumping.
㉔ Stop all operations. Of note, Cutter and Crease will move to the upper limit.
㉕ Double Feed Detection
Transmittance of the double feed sensor is shown as an integer between 0 and 1023.
The umber 1023 represents the state in which there is no sheet under the sensor, while
the number closer to zero indicates that thicker sheets have been detected by the
sensor.
: paper sheets are being loaded.
: no paper sheets loaded.
㉖ Return to SERVICE MENU Screen.

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

3- (3) SPEED Screen

① Regarding suction adjustment and speed change, refer to “5.1 Adjustments on the
paper feed” in Operation Manual.

3- (4) FEED Operation Screen

① FEED ROLLER ←、→ ⇔ ←、→

←：Feed belt will rotate positively by pressing this once. It will stop by pressing it again.
→：Feed belt will rotate negatively by pressing this once. It will stop by pressing it again.

② FEED TABLE ↑、↓

↑：FEED TABLE will move upward while this is being pressed.
↓：FEED TABLE will move downward while this is being pressed.

③ VACUUM OFF ⇔ ON
Vacuum motor will be turned ON and OFF.

④ BLOW OFF ⇔ ON
Blow motor will be turned ON and OFF.

⑤ RETURN
Return to Manual Operation Screen.

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3- (5) SLITTER Operation Screen

① CURNT POS
The values of Slitter’s current positions are shown.
② ↑、↓
↑：Slitters will move to the end while this is being pressed.
↓：Slitters will move to the front while this is being pressed.
③ RETURN
Return to Manual Operation Screen.

3- (6) INPUT DATA CHECK Screen

ON
OFF

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① PPR L/EDGE SENS 1（Origin sensor）

The sensor lamp will be turned off when shielded and
turned on when transmitted.
The lamp on the screen will be turned on when shielded
and turned off when transmitted.

② C/MARK SENS（Cut mark sensor）

The sensor lamp (orange) will be turned on when
detecting black color and turned off with no detection.
The lamp on the screen will be turned on when detecting
black color and turned off with no detection.
How to adjust.（ Page50）

③ PPR L/EDGE SENS 2（Stop sensor）

The sensor lamp will be turned on when shielded and
turned off when transmitted.
The lamp on the screen will be turned on when shielded
and turned off when transmitted.

④ CUTTER UP/LMT SW
The lamp on the screen will be turned on when the
switch is on.

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⑤ SLTR 1-4 HM POS

The sensor lamp will be turned off when shielded and
turned on when transmitted.
The lamp on the screen will be turned on when shielded
and turned off when transmitted.

⑥ COVER SENS A, B
The sensor lamp will be turned off when shielded and
turned on when transmitted. The lamp on the screen will
be turned off when shielded and turned on when
transmitted.

⑦ DOUBLE FEED SENSOR

The lamp on the screen will be turned off when shielded
and turned on when transmitted.

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⑧ INPUT SENS
The lamp on the screen will be turned on when shielded
and turned off when transmitted.

⑨ TBL LW/LMT SW
The lamp on the screen will be turned on when switched
on.

⑩ FD TBL UP/SENS
The sensor lamp will be turned off when shielded and
turned on when transmitted.
The lamp on the screen will be turned off when shielded
and turned on when transmitted.

⑪ SERVO ALERT
The lamp will be turned on if an error occurs on the servo motor; the lamp stays off when
no error condition exists.

⑫ SERVO POSITIONED
The lamp stays on while the servo motor is not running and stays off while the motor is
running.

⑬ SERVO ENCODER A, B
These are encoders for detecting the position of the servo motor.

⑭ SLITTER ENCODER 1～4 A, B

These are encoders for detecting the positions of slitter motors.

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⑮ CRSR UP/SENS
⑯ CRSR LW/SENS
The sensor lamp will be turned off when shielded and
turned on when transmitted.
The lamp on the screen will be turned off when shielded
and turned on when transmitted.

⑰ XPERFO ORIGIN SENS

The lamp on the screen will be turned on when shielded
and turned off when transmitted.

⑱ XPERFO EXIST
The lamp on the screen turns on when the harness is
connected to the machine. It turns off when the
harness is disconnected.

⑲ OP CONVEYER
The lamp on the screen turns on when the harness is
connected to the machine. It turns off when the
harness is disconnected.

⑳ RETURN
Return to Manual Operation Screen.

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

3- (7) LANGUAGE Screen

AeroCut Prime

AeroCut One / Velocity

① Language
Select an appropriate language. The language of the touch panel will switch on. English
is selected at the time of shipment.
(Languages that are not available at present cannot be selected)
A FRENCH LANGUAGE PASSWORD is set for switching to French. Enter the password
for switching.

② RETURN
Return to Service menu Screen.

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 AeroCut Prime/ One/ Velocity SERVICE MANUAL

3- (8) MAINTENANCE Screen

AeroCut Prime

AeroCut One / Velocity

① Distance between guillotine and creaser. [mm]

② Distance between stop sensor and guillotine. [mm]
③ Distance between origin sensor and Cutmark sensor. [mm]
④ Distance between origin sensor and stop sensor. [mm]
⑤ Distance between origin sensor and Y-Perfo. [mm]
⑥ Distance between origin sensor and X-Perfo. [mm]
⑦ Total number of re-feed in case double feed is occurred. [times]
⑧ The number of times that the machine checks double-feed. [times]
⑨ Initial position of X-Perfo.
⑩ Speed of slitter unit movement when fine adjusting slitter positions.
⑪ Width of gutter. →Default setting, do not change.
⑫ Paper vacuuming time when the feed table is lifted to the upper limit. [sec]
⑬ Distance between targeted positions and the points where slitter units start fine
adjustment when changing slitter positions.
⑭ Go to Maintenance Screen 2
⑮ This is to set either mm or inch as the measurement input unit.
⑯ Return to Service menu Screen.

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① Total number of processed Guillotine. [times]

② Total number of processed Crease. [times]
③ Total number of processed paper. [sheets] Not changeable
④ Operation time of Slitter 1~4. [hours : minutes]
⑤ Operation time of Feed table. [hours : minutes]
⑥ Slitter 1~4 Initial position. [mm]
⑦ Switch to activate/inactivate an optional unit (Y-Perfo)
⑧ Switch to activate/inactivate an optional unit (X-Perfo)
⑨ Machine Number.
⑩ Return to Maintenance Screen 1.

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4. Paper jam

① Enter MANUAL CONTROL screen, press < > buttons to inch the rollers forward/backward
and remove the jammed paper.
If paper is stuck around the guillotine section, press CUTTER to cycle the guillotine to chop
jammed paper.

MANUAL CONTROL screen

MANUAL CONTROL screen

② Detach Sponge roller and Slitter cover if necessary, and remove jammed paper.

Remove screws

Slitter cover

Sponge roller

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Note.
Do not attach Slitter cover on Washer
and Screw. This may cause paper jam.

Washer & screw

Note.
Remove paper in waste box before the
waste bin becomes full. It may cause
paper strips remain inside the machine
and cause paper jam.

Waste box
Note.
If paper jam often occurs, make sure that paper strip is not left in the indicated sections.
・Inside of Slitter head
・Inside of Guillotine cover
・Inside of Crease

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5. Replacement of parts
5- (1) Slitter Unit
Front side
① Remove Timing Belt from pulley.
② Disconnect the harness.
③ Remove screws.

Back side
④ Loosen Idler and remove Timing Belt.
⑤ Disconnect the harness.
⑥ Remove screws.

In side
⑦ Remove screws and cover.

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⑧ Pull Slitter Units out.

Note.
Shaft and Screw shaft shown on below figure might get rusty if touched by bare hands.
Put gloves on hands when you detach slitter shaft.

Screw shaft

Shaft

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5- (2) Slitter head

① Remove screws and cover.

② Remove Retaining ring-E.

Pull Idler Shaft out.

③ Remove screws.

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④ Remove screws.

Note.
When fixing the shafts, tighten the screw in the center position

Small hole

Screw

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Note.
There are 2 different types of idler shaft, mentioned on procedure ②, used on Margin Slitter
Unit and Gutter Slitter Unit. Refer to the marks as shown on below images to avoid putting
wrong idler shaft.

Margin Slitter unit Gutter Slitter unit

Red marker Blue marker

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Note.
Movement of slitter head is not good.
..Especially when a slitter movement is heavy. Cross recessed head screws

Please operate slitter head to find

the position where the movement is heavy.

Please stop slitter head and

loosen “cross recessed head screws”,
then tighten it again.

Note. Bolts
It sounds strange while a slitter unit is moving.
..Especially when it sounds strange.

Please operate slitter head to find

the position where it sounds strange.

Please stop slitter head and

loosen “Bolts”, then tighten it again.

When “Bolts” is tighten, please be careful

not to make any space between
“Slitter moving nut” and “Bracket”.

This space may happen “slitter rattle”

so that it could make inaccurate cutting
by slitter unit.

For more smooth movement of slitter unit,

please put some of silicone oil on screw shaft. Screw shaft Bracket
When it is done, please be careful not to put
silicone oil on carrying roller. Oil on carrying
roller might cause inaccurate cutting result.

Slitter moving nut

Slitter rattle

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5- (3) Guillotine Unit

① Check if the locating metal plate is in contact with the cutter unit.
This will be a mark for reattachment.
② Remove screws and Guillotine Cover.
③ Remove screws and pull Guillotine Unit out.

Locating
metal plate

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5- (4) X-perforator blade

① Remove covers.

② Move Perforation blade holder to the center by hand. Be careful not to touch
Perforation blade.

Perforation
blade holder

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③ Remove blade by pulling Perforation blade holder down.

Perforation blade

Note.
Attach Blade in shown way that blue rings should be together.

OK

NG

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5- (5) Y-perforator blade

① Remove covers.

② Remove blades.

Note.
Blade is double sided.

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5- (6) Feed belt Unit

① Remove screws and cover.

Cover

② Disconnect the harness.

Connector

③ Feed belt unit can be removed after bolts are removed.

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6. Adjustment

6- (1) Feed settings

(a) Blower

Standard Value

Input 10 in case paper is too

heavy to feed.
There will be possibility of double
feed if paper is too thin. In this
case, input 5.

Ensure that LONG BLOW is shown on

the screen. There is possibility of empty
feed.

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(b) Aligner
① Check angle of aligner by position of a hole in below picture when attaching the feed belt
unit.

Hole

Guide

② It is factory setting if Feed belt unit is attached so that a small hole contacts a big hole.

Hole position

Default
Status ― Parallel to Guide
（FactorySetting）
Effectiveness of
High Low None
Aligner

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(c)Feed area mechanical adjustments

(1) Lower Blower position

Blower base

Blower

Adjust the height by

loosening screws.

Note.
Do not remove screws because blower will drop.

Range of Value H
0.5～1.0mm

Friction surface

Blower base

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(2) Separator position

Separator

Adjust the height by

loosening screws

Range of Value H
0.5～1.0mm

Separator must be placed on higher position than friction surface.

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(3) Feed belt unit position

Adjust the height by

loosening screws

Adjust bolts
This will be a mark for reattachment.

Lift and fix Feed belt unit with 2mm Ensure that it is parallel to
thick paper inserted as above figure. the Feed guide by sight.

Feed belt unit

Feed guide

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(4) Feed sensor position

When the feed table is upper dead point, the proper gap between the feed table and the
feed belt is 2±0.5mm (0.08”±0.02”).
Loosen the screws and adjust the position of the feed sensor properly.

Feed belts

Screws Feed sensor Feed table

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(5) Parallelism of basement

① In case that you detached the basement for the purpose of parts replacement etc.,
the basement can be attached parallel by pressing the base against Locating metal
plate.
(Ensure that the basement is put on Locating metal plate when you detach it)

Locating
metal plate

Do not loosen
this screw.

② Please detach this part below in case that the upper surface of the basement is not
parallel.

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③ Settle a reference from two delivery rollers and adjust parallelism of the base with
tolerance within 0.3 mm between A and B.

Difference between A and B should be

within 0.3 mm.

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6- (2) Cut mark sensor

① Remove the sensor cover.

② Adjust the switch at “D” (D⇔L).
③ Shine the red light on the TEST MARK (GRAY).
④ Turn the volume from “MAX” to “MIN” slowly.
Stop at the position where both orange LED and green LED light.
⑤ Ensure that the orange LED lights when it senses the TEST MARK (GRAY) and
the orange LED does not light when it senses the white part of the TEST MARK.

In addition to above, ensure that the green LED lights at all times.
(If the green LED lights off sometime, the sensor may detect cut marks
inconsistently.

Volume

Switch
(Ｄ⇔Ｌ)

Cutmark
sensor

LED(Orange) LED(Green) RED LIGHT

TEST MARK (Black)
TEST MARK (Gray)

D L
MAX

MIN

Adjust it with a narrow Minus-head screwdriver.

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6- (3) PCB setting (AeroCut Prime)

Subject How to adjust

Origin Sensor Turn VR3 fully in clockwise.
Turn VR4 on CPU Board in clockwise with paper (77gsm).
Stop Sensor When D20 on CPU board turns off, turn VR3 in clockwise for
two division from this position.
Turn VR2 on CPU Board fully in anticlockwise.
Adjust VR1 on CPU Board with paper (126gsm) so that Double
feed detection counter on Manual Operation Screen shows
Double Feed Sensor approximately 500. After this procedure, ensure that Double
feed detection shows more than 40 with paper (350gsm). If this
value is less than 40, adjust volume so that it shows more than
40.

D20

D3

VR2

VR3 VR4 VR1

Double feed counter

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Subject How to adjust

Feed Sensor Turn VR15 fully in clockwise.
Adjust voltage to 0.310V by turning VR8 on I/O Board with
attaching a voltmeter to TP6 and TP7 and pressing X_PERFO
Pulse Motor Driver
which is shown on MANUAL CONTROL screen. After that
for Cross perforation
adjust voltage to 0.100V by turning VR7 on I/O Board without
pressing any button.
Origin Sensor Turn VR1 fully in clockwise.
for Cross perforation
No subject Turn VR14 fully in clockwise.

VR1 VR8 VR7

MANUAL CONTROL screen

TP7

TP6 VR14 VR15

D66

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6- (4) PCB setting (AeroCut One/Velocity)

Subject How to adjust

Origin Sensor Turn VR3 fully in clockwise.
Turn VR4 on CPU Board in clockwise with paper (77gsm).
Stop Sensor When D20 on CPU board turns off, turn VR3 in clockwise for
two division from this position.
Turn VR2 on CPU Board fully in anticlockwise.
Adjust VR1 on CPU Board with paper (126gsm) so that Double
feed detection counter on Manual Operation Screen shows
Double Feed Sensor approximately 500. After this procedure, ensure that Double
feed detection shows more than 40 with paper (350gsm). If this
value is less than 40, adjust volume so that it shows more than
40.

D20

D3

VR2

VR3 VR4 VR1

Double feed counter

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Subject How to adjust

Feed Sensor Turn VR15 fully in clockwise.
Pulse Motor Driver Not available on AeroCut One/Velocity. Turn VR7 and VR8 on
for Cross perforation I/O Board fully in anticlockwise.
Origin Sensor Not available on AeroCut One/Velocity. Turn VR1 fully in
for Cross perforation clockwise.
No subject Turn VR14 fully in clockwise.

VR1 VR8 VR7

TP7

TP6

VR14 VR15

D66

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6- (5) Accuracy adjustment

(a) Length adjustment
① Regarding Length adjustment, refer to “5.5.2 If the cut measurement does not
match the input value” in Operation Manual.
② Overwrite the initial setting value when you finished adjustment. .

AeroCut Prime AeroCut One / Velocity

ADJUST screen
ADJUST screen Double-Click

Double-Click

Enter the service password.

Enter the service password.

③ The values shown on the screen will be 0 after overwriting.

The ×1.000 (length magnification) part will not become ×1.000 by double-clicking the
top-right corner (will not be stored internally).
④ If you prefer to reset values to factory settings, amend values shown on the Service
Menu screen according to data which is attached inside of the front cover.
（ Page13）

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7. How to make layout

7- (1) Prime general template

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7- (2) One general template

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7- (3) General template(inch)

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7- (4) How to use barcode

(a) Contents of Barcode
Type：CODE128
Detail：7 digits as listed order below.
3 digits
Prime MANUSET ：001～100
Machine No.
Machine Aero Cut or
0～9 ※ FLEXMODE：101～150
One
PRESET※ ：200～552

Prime P
A C 0～9 001～552
One/Velocity O
※： If PRESET job is selected, it is possible to run a job even if Machine No. is
different.

(b) How to print

Barcode should be printed at almost the same level of Cut Mark and its length must be
more than 5mm.
The width of barcodes must be within a range of 35mm to 45mm.

35mm ~ 45mm
More than 5mm Cut Mark

The center of a barcode should be put on 120mm from the further paper edge.

120mm

Feeding direction

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(c) How to set Machine No.

Double tap on bottom left corner of MANUAL/SPEED screen.
After a new window shows up, input a number from a range of 0 to 9 as the Machine No.
if a user has several machines and every machine has different data.
This number should be used to identify multiple machines.
If it is not necessary to identify, it does not matter if this Machine No. is same.
Factory setting is 0.

Prime

One / Velocity

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(d) Barcode with USERDATA

Barcode is used to call up USERDATA from memory.
Therefore, in case USERDATA is not pre-programmed in memory, it is impossible to call
up data and operate.
Note that if there is a difference between USERDATA and the actual contents of printed
materials, printed materials will not be finished correctly.

Using barcode without Plug-in Software

① Ceate a job program by MANUSET or FLEXMODE, and memorize it as USERDATA.
(Refer to Operation Manual 3.5 SAVE / READ)
② Refer to USERDATA No. (3 digits) and create 7 digits Barcode.(Ex: If USERDATA No.
is 10, machine is Prime and Machine number is 0, Barcode should be ACP0010.)
③ According to the section 1. Detail of Barcode, put the barcode on an artwork and
print.
④ Set the prints and select Barcode Job Check or Barcode Job Change on the screen.
Then press the START.

Using barcode with Plug-in Software

① After starting Illustrator or InDesign, create job program by Plug-in and save it into
AeroCut. (Refer to Operation Manual of Plug-in (2)-(d)-③)
② Tick Barcode and press OK. Then barcode is generated and put on the artboard
automatically.
③ Print the artwork.
④ Set the prints and select Barcode Job Check or Barcode Job Change on the screen.
Then press the START.

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(e) PRESET Job Number list

Metric
350×500 SRA3
NO. Description NO. Description
200 BUSINESS CARD 55x85 220 BUSINESS CARD 55x85
201 BUSINESS CARD 50x85 221 BUSINESS CARD 50x85
202 BUSINESS CARD 55x90 222 BUSINESS CARD 55x90
203 BUSINESS CARD 50x90 223 BUSINESS CARD 50x90
204 PHOTO L 88.9x127 224 PHOTO L 88.9x127
205 PHOTO 2L 127x178 225 PHOTO 2L 127x178
206 SRA3 320x450 226 SRA3_DIV 3
207 A3 297x420 227 SRA3_DIV 4
208 A4 210x297 228 A3 297x420
209 A5 148x210 229 A4 210x297
210 A6 105x148 230 A5 148x210
211 CD JACKET 120x120 231 A6 105x148
212 CD JACKET 120x240 232 CD JACKET 120x120
213 CREASE 250 233 CREASE 225
216 A4 210x297 PERFO 148.5 234 A4 210x297 PERFO 148.5
A3 A4(landscape)
NO. Description NO. Description
240 BUSINESS CARD 55x85 260 BUSINESS CARD 55x85
241 BUSINESS CARD 50x85 261 BUSINESS CARD 50x85
242 BUSINESS CARD 55x90 262 BUSINESS CARD 55x90
243 BUSINESS CARD 50x90 263 BUSINESS CARD 50x90
244 PHOTO L 88.9x127 264 PHOTO L 88.9x127
245 PHOTO 2L 127x178 265 PHOTO 2L 127x178
246 A3_DIV 3 266 A4_DIV 3
247 A3_DIV 4 267 A4_DIV 4
248 A4 210x297 268 A5 148x210
249 A5 148x210 269 A6 105x148
250 A6 105x148 270 CD JACKET 120x120
251 CD JACKET 120x120 271 CREASE 148.5
252 55x170 CREASE 85 272 CD JACKET 120x240
253 55x180 CREASE 90 273 55x170 PERFORATE 55
254 CREASE 210 274 50x170 PERFORATE 55
255 A4 210x297 PERFO 148.5 275 55x180 PERFORATE 55
276 50x180 PERFORATE 55

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Metric
A4 (portrait) SUPER B
NO. Description NO. Description
280 BUSINESS CARD 55x85 440 BUSINESS CARD 55x85
281 BUSINESS CARD 50x85 441 BUSINESS CARD 50x85
282 BUSINESS CARD 55x90 442 BUSINESS CARD 55x90
283 BUSINESS CARD 50x90 443 BUSINESS CARD 50x90
284 PHOTO L 88.9x127 444 PHOTO L 88.9x127
285 PHOTO 2L 127x178 445 PHOTO 2L 127x178
286 A6 105x148 446 SRA3 320x450
287 CD JACKET 120x120 447 A3 297x420
288 55x170 CREASE 85 448 A4 210x297
289 55x180 CREASE 90 449 A5 148x210
290 A4 210x297 PERFO 148.5 450 A6 105x148
291 55x180 PERFORATE 55 451 LEGAL 215.9x355.6
292 50x180 PERFORATE 55 452 LETTER 215.9x279.4
453 CD JACKET 120x120
454 CREASE 241.3
455 A4 210x297 PERFO 148.5
LEDGER LEGAL
NO. Description NO. Description
460 BUSINESS CARD 55x85 480 BUSINESS CARD 55x85
461 BUSINESS CARD 50x85 481 BUSINESS CARD 50x85
462 BUSINESS CARD 55x90 482 BUSINESS CARD 55x90
463 BUSINESS CARD 50x90 483 BUSINESS CARD 50x90
464 PHOTO L 88.9x127 484 PHOTO L 88.9x127
465 PHOTO 2L 127x178 485 PHOTO 2L 127x178
466 LETTER 215.9x279.4 486 LEGAL_DIV 2
467 LEDGER_DIV 3 487 LEGAL_DIV 3
468 LEDGER_DIV 4 488 LEGAL_DIV 4
469 LEGAL 215.9x355.6 489 LETTER 215.9x279.4
470 CD JACKET 120x120 490 CD JACKET 120x120
471 CREASE 215.9 491 CD JACKET 120x240
472 55x170 CREASE 85 492 CREASE 177.8
473 55x180 CREASE 90 493 55x170 PERFORATE 55
474 55x170 PERFORATE 55 494 50x170 PERFORATE 55
475 50x170 PERFORATE 55 495 55x180 PERFORATE 55
476 55x180 PERFORATE 55 496 50x180 PERFORATE 55
477 50x180 PERFORATE 55

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Metric
OFICIO LETTER (landscape)
NO. Description NO. Description
500 BUSINESS CARD 55x85 520 BUSINESS CARD 55x85
501 BUSINESS CARD 50x85 521 BUSINESS CARD 50x85
502 BUSINESS CARD 55x90 522 BUSINESS CARD 55x90
503 BUSINESS CARD 50x90 523 BUSINESS CARD 50x90
504 PHOTO L 88.9x127 524 PHOTO L 88.9x127
505 PHOTO 2L 127x178 525 PHOTO 2L 127x178
506 OFICIO_DIV 2 526 LETTER_DIV 2
507 OFICIO_DIV 3 527 LETTER_DIV 3
508 OFICIO_DIV 4 528 LETTER_DIV 4
509 LETTER 215.9x279.4 529 CD JACKET 120x120
510 CD JACKET 120x120 530 CD JACKET 120x240
511 CD JACKET 120x240 531 CREASE 139.7
512 CREASE 165.1 532 55x170 PERFORATE 55
513 55x170 PERFORATE 55 533 50x170 PERFORATE 55
514 50x170 PERFORATE 55 534 55x180 PERFORATE 55
515 55x180 PERFORATE 55 535 50x180 PERFORATE 55
516 50x180 PERFORATE 55
LETTER (portrait)
NO. Description
540 BUSINESS CARD 55x85
541 BUSINESS CARD 50x85
542 BUSINESS CARD 55x90
543 BUSINESS CARD 50x90
544 PHOTO L 88.9x127
545 PHOTO 2L 127x178
546 CD JACKET 120x120
547 55x170 CREASE 85
548 55x180 CREASE 90
549 55x170 PERFORATE 55
550 50x170 PERFORATE 55
551 55x180 PERFORATE 55
552 50x180 PERFORATE 55

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Inch
SUPER B ARCH-B
NO. Description NO. Description
320 BUSINESS CARD 2''x3.5''S 340 BUSINESS CARD 2''x3.5''S
321 BUSINESS CARD 2''x3.5''D 341 BUSINESS CARD 2''x3.5''D
322 BUSINESS CARD 3.5''x4'' 342 BUSINESS CARD 3.5''x4''
323 PHOTO L 3.5''x5.0'' 343 PHOTO L 3.5''x5.0''
324 PHOTO 2L 5.0''x7.0'' 344 PHOTO 2L 5.0''x7.0''
325 POST CARD 3.0''x5.0'' 345 ARCH-B_DIV 2
326 POST CARD 3.5''x5.5'' 346 ARCH-B_DIV 3
327 POST CARD 4.0''x6.0'' 347 ARCH-B_DIV 4
328 POST CARD 8.0''x10.0'' 348 POST CARD 3.0''x5.0''
329 LEGAL 8.5''x14.0'' 349 POST CARD 3.5''x5.5''
330 LETTER 8.5''x11.0'' 350 POST CARD 4.0''x6.0''
331 LABEL 4.25''x5.0'' 351 POST CARD 8.0''x10.0''
332 CD JACKET 4.7''x4.7'' 352 LEGAL 8.5''x14.0''
333 CD JACKET 4.7''x9.44'' 353 LETTER 8.5''x11.0''
354 LABEL 4.25''x5.0''
355 CD JACKET 4.7''x4.7''
356 CD JACKET 4.7''x9.44''
LEDGER LEGAL
NO. Description NO. Description
360 BUSINESS CARD 2''x3.5''S 380 BUSINESS CARD 2''x3.5''S
361 BUSINESS CARD 2''x3.5''D 381 BUSINESS CARD 2''x3.5''D
362 BUSINESS CARD 3.5''x4'' 382 BUSINESS CARD 3.5''x4''
363 PHOTO L 3.5''x5.0'' 383 PHOTO L 3.5''x5.0''
364 PHOTO 2L 5.0''x7.0'' 384 PHOTO 2L 5.0''x7.0''
365 LETTER 8.5''x11.0'' 385 LEGAL_DIV 2
366 LEDGER_DIV 3 386 LEGAL_DIV 3
367 LEDGER_DIV 4 387 LEGAL_DIV 4
368 POST CARD 3.0''x5.0'' 388 POST CARD 3.0''x5.0''
369 POST CARD 3.5''x5.5'' 389 POST CARD 3.5''x5.5''
370 POST CARD 4.0''x6.0'' 391 POST CARD 8.0''x10.0''
371 POST CARD 8.0''x10.0'' 392 LETTER 8.5''x11.0''
372 LEGAL 8.5''x14.0'' 393 LABEL 4.25''x5.0''
373 LABEL 4.25''x5.0'' 394 CD JACKET 4.7''x4.7''
374 CD JACKET 4.7''x4.7'' 395 CD JACKET 4.7''x9.44''
375 CD JACKET 4.7''x9.44''

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Inch
LETTER (landscape) LETTER (portrait)
NO. Description NO. Description
400 BUSINESS CARD 2''x3.5''S 420 BUSINESS CARD 2''x3.5''S
401 BUSINESS CARD 2''x3.5''D 421 BUSINESS CARD 2''x3.5''D
402 BUSINESS CARD 3.5''x4'' 422 BUSINESS CARD 3.5''x4''
403 PHOTO L 3.5''x5.0'' 423 PHOTO L 3.5''x5.0''
404 PHOTO 2L 5.0''x7.0'' 424 PHOTO 2L 5.0''x7.0''
405 LETTER_DIV 2 425 POST CARD 3.0''x5.0''
406 LETTER_DIV 3 426 POST CARD 3.5''x5.5''
407 LETTER_DIV 4 427 POST CARD 4.0''x6.0''
408 POST CARD 3.0''x5.0'' 428 POST CARD 8.0''x10.0''
409 POST CARD 3.5''x5.5'' 429 LABEL 4.25''x5.0''
410 POST CARD 4.0''x6.0'' 430 CD JACKET 4.7''x4.7''
411 POST CARD 8.0''x10.0''
412 LABEL 4.25''x5.0''
413 CD JACKET 4.7''x4.7''
414 CD JACKET 4.7''x9.44''

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8. Electricity related
8- (1) Equipment, Electric circuit, and parts

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8- (2) Board Details

①CPU BOARD

②I / O BOARD

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③ Wiring Details

Slitter 1 origin sensor Crease lower sensor

Slitter 2 origin sensor
Origin sensor for Slitter 4 motor Servomotor
Slitter 3 origin sensor Cross Perforation driver
Slitter 3 motor
Slitter 4 origin sensor DC power
Feed upper sensor Slitter 2 motor supply
Cutter motor Slitter 1 motor
Cover sensor B

Cutter upper limit switch

Feed table lower limit switch
Cover sensor A
Connect for Cross Perforation
Crease upper sensor
Feed sensor

Conveyer Crease motor

sensor Feed table
motor Vacuum fan motor
Connect for Feed belt motor
Conveyer Side Blow fan motor Ionizer Jump-perforation 2
Blow fan motor Jump-perforation 1 Conveyer motor

Servomotor
driver

Double feed sensor

DC power
supply

Stop sensor
Double feed
sensor Touch panel Cut mark sensor
OP Barcode scanner LAN Board Origin sensor
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8- (3) Input/Output LED Details

D33：
3.3V(TP4-5)
③

②
D14：
5V(TP1-5)

D15：
24V(TP2-5)

①LED on Lower Side

D51：OUTPUT-None
D50：OUTPUT-None
D01：OUTPUT-Cutter motor move forward
D02：OUTPUT-Cutter motor move reverse
D06：OUTPUT-Slitter 4 move outside
D08：OUTPUT-Slitter 4 move inside
D09：OUTPUT- Slitter 3 move outside
D10：OUTPUT- Slitter 3 move inside
D16：OUTPUT- Slitter 2 move outside
D17：OUTPUT- Slitter 2 move inside
D38：OUTPUT-None
D19：OUTPUT- Slitter 1 move outside
D21：OUTPUT- Slitter 1 move inside
D39：OUTPUT-Conveyer motor

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②LED on Left Lower Side

D47：OUTPUT-Jump-perforation 1
D46：OUTPUT-Jump-perforation 2
D45：OUTPUT-None
D43：OUTPUT-Side Blow fan motor
D41：OUTPUT-Ionizer
D36：OUTPUT-Feed table move down
D35：OUTPUT-Feed table move up
D31：OUTPUT-Blow fan motor
D30：OUTPUT-Feed belt move forward
D29：OUTPUT-Feed belt move reverse
D27：OUTPUT-Vacuum fan motor
D25：OUTPUT-Crease motor move reverse
D23：OUTPUT-Crease motor move forward

③LED on Left Upper Side

D48：INPUT-None
D40：INPUT-None
D24：INPUT- Connect for Conveyer
D42：INPUT-Cutter upper limit switch
D34：INPUT-Feed table lower limit switch
D26：INPUT-None
D11：INPUT-Connect for Cross Perforation
D04：INPUT-Crease upper sensor
D62：INPUT-Cover limit switch B
D59：INPUT-Cover limit switch A
D56：INPUT-Crease lower sensor
D52：INPUT-Slitter 4 origin sensor
D44：INPUT-Slitter 3 origin sensor
D37：INPUT-Slitter 2 origin sensor
D28：INPUT-Slitter 1 origin sensor
D13：INPUT-Cut mark sensor
D20：INPUT-Stop sensor
D03：INPUT-Origin sensor

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④LED on Upper Side

D18：INPUT-Feed table upper sensor

D49：INPUT-Slitter 4 encoder pulse A
D55：INPUT-Slitter 4 encoder pulse B
D57：INPUT-Slitter 3 encoder pulse A
D60：INPUT-Slitter 3 encoder pulse B
D63：INPUT-Slitter 2 encoder pulse A
D64：INPUT-Slitter 2 encoder pulse B
D05：INPUT-Slitter 1 encoder pulse A
D12：INPUT-Slitter 1 encoder pulse B
D32：INPUT-Origin sensor for Cross Perforation
D65：INPUT-Conveyer sensor
D66：INPUT-Feed sensor
D67：INPUT-None
D58：INPUT-Servo alert
D61：INPUT-Servo positioned
D54：INPUT-Servo motor encoder pulse A
D53：INPUT-Servo motor encoder pulse B

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8- (4) Tap Voltage Details

CPU BOARD TP6 +24 V
TP7 GND

+3.3V LED
TP9 GND (TP4-TP5)
TP8 +5 V
TP4 +3.3V

+5 V LED
(TP1-TP5)

TP1：Power Supply for CPU TP1 +5 V

TP2：Power Supply for Touch Panel TP2 +24 V

TP3：Input from DC Power Supply TP3 +24 V

TP4：Power Supply for Pulse controller TP5 GND

TP5：Ground
TP6：Power Supply for Sensors and Control Systems
TP7：Ground +24 V LED
TP8：Power Supply for Slitter encoders (TP2-TP5)
TP9：Ground

I/O BOARD

TP1 +24 V
TP2 GND

TP3 +24 V
TP4 GND

TP1：Power Supply for Motors

TP2：Ground
TP3：Power Supply for Sensors and Control Systems
TP6 GND
TP4：Ground
TP5 +5 V
TP5：Power Supply for Slitter encoders
TP6：Ground

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8- (5) Wiring Details

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8- (6) Servo motor driver setting

① No need for setting after shipment as it will be set prior to shipment.

② However, special software is required to change the factory settings.
③ The software is available for download from the manufacturer’s website, which is
accessible via the following link. Download the Setup support software (PANATERM
V5.0) along with the operating manual for the setup support software. Also download the
“WHEN in trouble” manual.
http://industrial.panasonic.com/ww/i_e/25000/fa_pro_acs_e/fa_pro_acs_e/a5.html
The latest version of the software as of August 2011 is version 5.0.
④ Install the software according to the downloaded operating manual.
⑤ Connect the USB cable (A Æ mini B) to the connector X1 for the driver to also install the
USB driver. For installation, refer to the downloaded operating manual.

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⑥ Start “PANATERM”.
⑦ Click “OK”.

⑧ Click “PARAMETER” of the tool bar on the main screen.

⑨ Selection of parameter to be read window is displayed.

⑩ Click “Read from the file”.
⑪ Click “OK”.

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⑫ Of the data we provided, select a data file with a file extension of “.prm5,” and click “OK”.

⑬ Click “Trans”.
⑭ Click “EEP” after the transmission is completed to complete the entire process.

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8- (7) Initial Setting of Touch Panel

(No setting is necessary after shipment, as it will be set prior to shipment)
① Turn on the power supply while pressing the top right corner of the touch panel. The
following screen will appear when successful.

① Japanese

② Run Mode

② After seeing that words on the screen, turn off the machine and turn it on again.

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9. Program update

9- (1) Software install

(a) Requirements
VT Transfer Tool
AVR STUDIO
for AeroCut One for AeroCut Prime
Supported OS Windows XP/VISTA/7/8 Windows XP/XP/VISTA/7
CPU Pentium 800 MHz processor Pentium 200 MHz processor
or equivalent or equivalent
Memory 256 MB or more 256 MB or more
Hard disk space 50 MB or more 300 MB or more 100 MB or more
Display 1024 × 768 screen 1024 × 768 screen
16 bit high color or better (minimum 800 × 600 screen)
Interface USB port USB port

(b) Confirmation of Accessories

USB cable AVRISP mkⅡ

DISK1 will not be used for installation.

It contains files such as AVR-related instruction manuals.
Please refer to them when needed.
2 CD-Rs

DISK 1 DISK 2

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(c) How to install VT Transfer Tool for AeroCut One/Velocity

Insert DISK2 in the CD/DVD drive and install it according to the following procedure.
(The procedure below is for WINDOWS XP)
Double click on “VTTransferTool¥ One¥VTTEHp4??.exe” of the CD/DVD.

① Next

② Next ③ Install

④ Finish

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(d) How to install VT Transfer Tool for AeroCut Prime

Insert DISK2 in the CD/DVD drive and install it according to the following procedure.
(The procedure below is for WINDOWS 7)
Double click on “VTTransferTool¥Prime¥VTTGHp6??.exe” of the CD/DVD.

① Select a language

② OK

③ Next

④ Next ⑤ Install

⑥ Finish

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(e) How to install AVR STUDIO

(The procedure below is for WINDOWS XP)
Double click on “AVR_TOOL¥ AvrStudio4Setup.exe” of the CD/DVD.

① Next ② I accept ･･･ ③ Next

④ Next ⑤ Next

⑥ Install

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⑦ Finish

Next is the update of AVR STUDIO.

Double click on “AVR_TOOL¥ AVRStudio4.18SP3.exe” of the CD/DVD.

① Next

② Finish

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Next is the installation of WINAVR.

Double click on “AVR_TOOL¥ WinAVR-20100110-install -install.exe” of the CD/DVD.

① Select a language

② OK
③ Next

④ I Agree ⑤ Next

⑥ Install ⑦ Finish

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⑧× (Close the Window)

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9- (2) Touch panel

(a) Connecting to a computer/VT Transfer Tool operation
If any changes are made to the touch panel content, we will send the data to you most
likely by e-mail.
For Prime：
The data format will look like “AeroCut_ prime_100.mu2” with a file extension of “.mu2”.
For One/Velocity：
The data format will look like “AeroCut_one_100.ms3” with a file extension of “.ms3”.
The figure “100” refers to a version, which means Version 1.00.
Save this data in a folder of your choice in your computer and upgrade the version as
follows:

① Remove the unit cover, and connect the USB cable provided with the unit to the back
of the touch panel as shown below. (The procedure below is for WINDOWS XP).

USB cable

② Turn on the power supply. If the installation of the USB driver is necessary at this point,
install the driver using DISK2, which contains the driver in the USB folder.

① Select the one at the bottom

③ Select the one at the bottom ② Next

④ Next ⑤ Select the one at the top ⑥ Next

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⑦ Next ⑧ Finish

③ Start up the computer and double click on (For AeroCut One/Velocity).

Start up the computer and double click on (For AeroCut Prime).

④ Click on Send screen data.

⑤ Select the folder in which you saved our screen data, select a file with a file extension
of ms3, and click on Send all data.

For One/Velocity：
Select where you saved the
“.ms3” file sent from us.

For Prime：
Select where you saved the
“.mu2” file sent from us.

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⑥ Click on “Yes.”

⑦ Click YES if a question, “Version of system program is new. Send to VT unit?” is asked.
If the question is not asked, you do not need to do anything.

⑧ The touch panel will make a peep sound when the transmission has completed.

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⑨ Click OK and finish by pressing Exit.

⑩ After your installing updated software, the direction you can see the below will remain
on the touch panel. After seeing that words on the screen, turn off the machine and
turn it on again.

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9- (3) CPU board

(a) AVRISP mkⅡconnection and AVR STUDIO operation
If any changes are made to the program content, we will send the data to you most
likely by e-mail.
The data format will look like “AeroCut_prime_100.hex” or “AeroCut_one_100.hex” with
a file extension of “.hex.” The figure “100” refers to a version, which means Version 1.00.
Save this data in a folder of your choice in your computer and upgrade the version as
follows:
① Remove the cover at the bottom of the front of the unit. Connect AVRISP mkⅡ
provided with the unit to CN7 of the CPU Board, and connect the USB cable to the
computer.

Connect it with the red line To Computer

on the left.

USB cable

② If the installation of the USB driver is necessary at this point, install the driver
following the procedure below (The procedure below is for WINDOWS XP).

① Select the one at the bottom

② Next

③ Select the one at the bottom ④ Next

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⑥ Change The following folder is selected by

⑤ Check the second one default: C:¥Program Files¥Atmel¥AVR Tools¥usb

⑦ Next

⑧ Next ⑨ Finish

③ Start up the computer and double click on Start ⇒ Program ⇒ Atmel AVR Tools
⇒ AVR Studio 4.

④ Click on Cancel.

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⑤ Click on AVR (Connect to the Selected AVR Programmer).

⑥ Select AVRISP mkⅡ for Platform, Select USB for Port, click on Connect.

⑦ If the following warning appears on the screen, AVRISP mkⅡfirmware upgrade is

necessary. Click on OK. If the warning does not appear on the screen, skip to ⑩.

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⑧ Click on Start Upgrade.

⑨ Disconnect the USB cable of AVRISP mkⅡand connect it again. After that, click on
OK. If AVR STUDIO has shut down, return to ③ and conduct the operation again.

⑩ Click on Main tab, select the Atmega2560 for Device and Signature Bytes.

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⑪ Click on Main tab and on Settings. Select 500 kHz for ISP Freq, click on Write, and
click on Close.

⑫ After clicking on Program tab, select the folder where the file was initially saved as
the save location. By clicking on Program, the transmission of the program will start.
(About 30 sec.)

Select where our “.hex” file was

initially saved.

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⑬ Click the LockBits tab, and click ▼ next to “No memory lock features enabled,” then,
select
“Further programming and verification disabled.” Click “program”.

⑭ The process is completed when the transmission of the program has finished.

⑮ From the next time onward, proceed in the order of ③,④,⑤,⑩,⑫, and ⑬.

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10. Cleaning & greasing

・Clean Rollers and Sensors properly.

・Rollers ahead and behind of Guillotine may affect accuracy if they are dirty.
・Stop sensor mirror may cause inoperativeness if it is dirty.

Stop sensor mirror

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11. Recommended replacement parts

A B C

D
F G

No. Parts name Parts No. Qty Remarks

A Slitter blade 7703-0270+ 2
(Margin, upper)
B Slitter blade 7726-8271 2
(Gutter, upper)
C Slitter blade (Lower) 51-596+ 6
D Perforator blade 61-061+ - For X-perfo. & Y-jump perfo.
E Perforator blade 61-061 - For Y-perfo.
F Blade receiver 7711-0410 - For Y-jump perfo. & Y-perfo.
G Blade receiver 7703-0531 1 For X-perfo.
Guillotine 61-045 1
Timing belt (Roller) 82-546 1 S3M 1146
Timing belt (Roller) 82-548 1 S3M 552
Timing belt (Roller) 82-547 1 S3M 528
Timing belt 82-562 1 S3M 285
(Main motor)
Timing belt 82-545 1 S3M 1014
For X perforator
Timing belt (Crease) 82-549 1 S5M 340
Timing belt (Slitter) 82-557 4 S3M 216
Feed belt 80-718 4 L750

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12. Troubleshooting

This occurs when the Safety cover ・ Cover Sensor either A or B, or both may be
or Stacker panel is opened. out of order.
If the screen below remains after ☞3- (6) INPUT DATA CHECK Screen
close the both cover. ・ The angle of the shield plate may be wrong.
1 ☞3- (6) INPUT DATA CHECK Screen
・ I/O Board may be out of order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

This occurs when the unit was ・ Clean the reflector under the Stop Sensor.
started with paper still remaining ☞10.Cleaning & greasing
inside the unit. ・ Either Origin Sensor, C/M Sensor, or Stop
If the screen below remains after Sensor may be out of order.
paper removal.
☞3- (6) INPUT DATA CHECK Screen
・ CPU Board may be out of order.
2
・ Wire breakage or connection failure may have
occurred.

This occurs when the paper did not When Feed Belt and Carrying Roller are both
pass through Origin Sensor at time rotating:
of paper feeding. ・ Paper guides (Small) hold the sheets too
If this occurs frequently (except tightly on the Feed table.
when there is no paper on Feed ・ Paper tip could remain inside of the machine.
Table) ・ Clean feed belts.
3 ・ Vacuum motor may be out of order.
・ Origin Sensor may be out of order.
☞3- (6) INPUT DATA CHECK Screen
・ I/O Board may be out of order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

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When Feed Belt is not rotating:

・ Feed Motor may be out of order.
・ I/O Board may be out of order.
・ CPU Board may be out of order.
3 ・ Wire breakage or connection failure may have
occurred.

When Carrying roller is not rotating:

・ Servo Motor and/or Driver may be out of
order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.
This occurs when the paper did not When Feed Roller is rotating:
pass between Origin Sensor and ・ Paper tip could remain inside of the machine.
Stop Sensor within a designated ・ Origin Sensor may be out of order.
period of time. ☞3- (6) INPUT DATA CHECK Screen
If this frequently occurs, ・ Stop Sensor may be out of order.
☞3- (6) INPUT DATA CHECK Screen
・ Slipping is caused by powdered paper at
Feed Roller.
・ Paper warpage may have occurred.
・ Slitter may be out of order.
4 ・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

When Carrying roller is not rotating:

・ Servo Motor and/or Driver may be out of
order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

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This occurs when Feed Table is ・ Feed Motor may be out of order.
overloaded. ・ Switch (TBL UP/LMT SW or TBL LW/LMT
If this occurs frequently, SW) may be out of order.

☞3- (6) INPUT DATA CHECK Screen

5 ・ Screws of the coupling may be loose.
・ I/O Board may be out of order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.
This occurs when Cutter or Crease When Cutter is overloaded:
are overloaded. ・ Paper tip could remain inside of the machine.
If this occurs frequently, ・ Paper double feeding.
・ Paper thickness is out of specification.
・ Cutter blade may be blunt.
・ Cutter Motor may be out of order.
・ Switch (CUTTER UP/LMT SW) may be out of
order.

☞3- (6) INPUT DATA CHECK Screen

・ I/O Board may be out of order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

6
When Crease is overloaded:
・ Paper tip could remain inside of the machine.
・ Paper double feeding.
・ Paper thickness is out of specification.
・ Crease depth adjustment may be set
incorrectly.
・ Crease Motor may be out of order.
・ Sensor (CRSR UP/SENS) may be out of
order.

☞3- (6) INPUT DATA CHECK Screen

・ I/O Board may be out of order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

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This occurs when Slitter Unit is ・ Paper tip could remain inside of the machine.
overloaded. ・ Slitter Movement Screws or shaft may be out
If this occurs frequently, of order.
・ Tension of Timing Belt may need to be
adjusted.
・ Screws of Timing Pulley need to be checked
for their tightness.
・ Sensor (SLTR1-4 HM POS) may be out of
order.
7
☞3- (6) INPUT DATA CHECK Screen
・ Origin Sensor’s location may be set
incorrectly.
・ Slitter Motor may be out of order.
・ I/O Board may be out of order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

This occurs when Cut Mark could ・ Cut Mark printing density needs to be
not be detected. checked.
・ Cut Mark Sensor needs to be re-adjusted.

8
☞6- (2) Cut mark sensor
・ Cut Mark Sensor may be out of order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.
Two or more sheets are fed at one ・ Fan out the paper sufficiently and jog the
time. paper to make the each of the sheets
If this occurs frequently, separately.
・ Adjust the volume of Blower FAN and
Vacuum Fan.

☞3- (3) SPEED Screen

9
・ Blow motor may be out of order.

Note:
Activate double-feed detection mode.

☞OPERATION MANUAL
「5.1 Adjustments on the paper feed section」

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This occurs when a servo error is ・ COVER SENS A, B may be out of order.
detected. ☞3- (6) INPUT DATA CHECK Screen
・ Servo Motor Driver may be out of order.
・ Servo Motor may be out of order.
10
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

This occurs at times of ・ Touch Panel may be out of order.

communication errors. ・ CPU Board may be out of order.
If this occurs frequently, ・ Wire breakage or connection failure may have
11 occurred.

This occurs at times that machine is ・ Switch (CUTTER UP/LMT SW) may be out of
operated when Cutter is not on top order.
dead center. ☞3- (6) INPUT DATA CHECK Screen
If this occurs frequently, ・ I/O Board may be out of order.
12
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

This occurs at times that machine is ・ Sensor (CRSR UP/SENS) may be out of
operated when Cutter is not on order.
bottom dead center. ☞3- (6) INPUT DATA CHECK Screen
If this occurs frequently, ・ I/O Board may be out of order.
13
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.

This occurs when the harness of ・ Check signals of a harness.

X-perfo is disconnected. ☞3- (6) INPUT DATA CHECK Screen
If it occurs although the harness are ・ I/O Board may be out of order.
not disconnected, ・ CPU Board may be out of order.
14
・ Wire breakage or connection failure may have
occurred.

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This occurs when X-perfo detects ・ Paper tip could remain inside of the machine.
overload or X-perfo moves beyond ・ Malfunction of X-Perfo.
its moving range caused by losing ・ I/O Board may be out of order.
steps and its location. ・ CPU Board may be out of order.
15 If this occurs frequently, ・ Wire breakage or connection failure may have
occurred.

This occurs when X-perfo moves ・ Paper tip could remain inside of the machine.
beyond initial position by losing ・ Malfunction of the origin sensor of X-perfo.
steps and its position ☞3- (6) INPUT DATA CHECK Screen
・ Malfunction of X-Perfo.
16
・ I/O Board may be out of order.
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.
This occurs when barcode cannot ・ Check if barcode is printed clearly and is
be read. clean.
If this occurs frequently, ・ Check if the position of barcode is correct.
・ Tipping the Barcode scanner unit can improve
17 accuracy of reading.
・ Malfunction of Barcode scanner
・ CPU Board may be out of order.
・ Wire breakage or connection failure may have
occurred.
This occurs when the format of the ・ Check if name of the machine (Prime or One
Barcode is incorrect. and machine number (0 – 9) is correct.
If this occurs frequently, ・ Check if the setting of the Plug-in is correct.
18

The dimensions of finished card are ・ Make it correct at ADJUST Screen.

19
different from the measurements ☞OPERATION MANUAL
you have input. 「5.5.2 If the cut measurement does not match
the input value」

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The lengths of finished cards are ・ Clean Carrying rollers.

uneaqual. ・ Clean Sensors.
・ Cutter blades could have got damaged and
20
got partly dull. Replace the cutter unit.

The widths of finished cards are ・ Clean Carrying rollers.

uneaqual. ・ Slitter blade could have got damaged and got
partly dull.
21
・ CPU Board may be out of order.
・ Servo Motor Driver may be out of order.
・ Servo Motor may be out of order.
Two or more sheets are fed at one ・ Fan out the paper sufficiently and jog the
time. paper to make the each of the sheets
If this occurs frequently, separately.
・ Adjust the volume of Blower FAN and
Vacuum FAN.
22 ☞3- (3) SPEED Screen
・Blow motor may be out of order.
Note:
Activate double-feed detection mode.

☞OPERATION MANUAL
「5.1 Adjustments on the paper feed section」
A sheet stops after moving slightly ・ Thick paper cannot be fed at higher speed
23 （with noise） and a sheet stop being fed with noise.
Please slow down the speed.
Paper jam occurs frequently. ・ Paper curl too much to be conveyed
smoothly.
・ The dimensions of the paper are different
24 from the measurements you input into the
machine.
・ Paper tip could remain inside of the machine.
(Origin sensor, Slitter, Cutter, Creaser, Perforator)
Paper remains at a Crease blade. ・Make Crease depth smaller.
25 ☞OPERATION MANUAL
「5.4 Creaser adjustment」
The movement of slitter block is not Please adjust slitter head.
26
smooth. Page. 36

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It sounds strange while slitter block Please adjust slitter head.

27
is moving. Page. 36

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UCHIDA YOKO CO., LTD.

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