MODEL M4

USER MANUAL
AMXMAN-09-01 REV 1

AUTOMETRIX, INC.
www.autometrix.com
support@autometrix.com
PH: 530-477-5065
FX: 530-477-5067
 Table of Contents

1 System Description
Carriage
Motors
Rails and Rack
Sensors
Cutting Head
Operator Controls
Electronics Cabinet and Power Supply
Control Panel
Cables
Vacuum Table and Blower
Cutting Surface
PatternSmith

2 System Operation
GLCD Keypad and Joystick
Vacuum Blowers
Pause / Restart / Cancel
Emergency Stop Mode

3 Plotting and Cutting

Startup
Vacuum Hold-Down
Cutting a Table

4 Plotting and Cutting Devices

Blades and Blade Holders
PatternSmith Settings

5 Maintenance
Precautions
Maintenance Note
Maintenance Schedule
Adjustment Instructions
6 Calibration Guide
Usercals File
Macro Based Calibration
Blade Angle Alignment
Device Offsets

7 Troubleshooting Guide
Troubleshooting Guidelines
Diagnostic Tools

8 Establishing an Ethernet Connection

Host Computer IP Configuration
M4 Electronics IP Configuration

9 Safety Precautions
Powered Mechanical
Electrical Hazards
Pneumatic Hazards
Vacuum Hazards
Racks (Material Handling Equipment)
Parts
Mechanical Maintenance and General Precautions

10 System Setup and Requirements

Electrical Power Requirements
Compressed Air Requirements
 1: System Description
The Autocut M4 is a precision cutting system designed for single- and low-ply
automated cutting applications. It includes a vacuum table, carriage, cutting head,
electronics cabinet, and control software.

Carriage
Your M4 carriage is designed for maximum strength with the lightest possible weight.

This lighter weight reduces forces on the system which means it will suffer less wear
and will have improved reliability.

Motors
The M4 carriage has four motors. Two drive the X-axis (the length of the table), one
drives the Y-axis (the width of the table), and one steers the cutting blade, called the
Theta axis. The X- and Y-axes are driven by a pinion attached directly to the motor
shaft.

Rails and Rack

Both X- and Y-axes use a rack and pinion drive system. The racks are oriented in an
inverted position (teeth down) so that dirt, dust, and cutting debris cannot collect in
them. This helps prevent cutting inaccuracies due to excessive drive resistance.

Attached to the vacuum panel edges are the X-axis rails, structural members that
provide linear accuracy along the X-axis. It is important to avoid subjecting the rails to
excessive force that could distort them.

Sensors
The cutting system uses six limit sensors to define the boundaries of the cutting area.
These are proximity sensors and are triggered when a steel object comes within a
predetermined distance.
The limit sensors serve two purposes. First, they are used in the process of finding
the ‘Home’ position and squaring the carriage to the table each time it is powered up.
Second, the positions of the limit switches and triggers define an “in bounds” rectangle
of maximum carriage motion. If the carriage moves beyond the ranges set by the
sensors, the limit sensors signal the controller to stop the carriage immediately.

Three of these sensors are located on the table rails and are used to define the X-axis
limits at the ends of the table. These limit sensors are called XA Low, XB Low, and XA
High. The remaining three sensors are mounted on the carriage assembly. These limit
sensors are called Y Low, Y High, and Theta. The Theta limit sensor, located on the
carriage is used only for aligning the Theta axis when homing. You can view their
locations on the diagram shown.

Cutting Head
The cutting head includes a pen holder, two
steered blade holders, and an optional air
drill. The blade holders can accept two types
of rolling blades, tangential blades, a rotary
punch, or a notch tool. The pen and blade
holders are actuated by adjustable pneumatic
pressure.
Operator Controls
The GLCD (Graphics LCD) touchscreen keypad and joystick provide operator control of
the carriage. From here, you can start, pause, or cancel cutting jobs, jog the carriage,
return home, and activate devices. The keypad display changes according to functional
states: startup, local, online (ready), online (finished), paused, and error conditions.

Electronics Cabinet and Power Supply

The electronics cabinet is located near the center of the table. It contains the power
supply, controller, interface board, and drive amplifiers for each motor. The controller
receives instructions from PatternSmith or the keypad and joystick, and translates them
into signals to the motor amplifiers (drives) that position the carriage and cutting head.
The electronics cabinet is normally connected to the host computer through an Ethernet
connection.
Control Panel
The on/off switch, cutting pressure controls, pause button, and emergency stop are
located on the table control panel.

Cables
All moving cables for the X- and Y- axes are enclosed in an Energy Chain (E-Chain).
The E-Chain for the X-axis is located on the ‘B side’ of the table, away from the
operator position. When cables eventually wear out, the E-Chain snaps open for easy
replacement of cables. (Contact Autometrix Customer Service for assistance when it is
time to replace your cables.)

Vacuum Table and Blower

The vacuum blower applies suction to the entire table, evenly holding your material in
place during the plotting and cutting process. (Additional vacuum blower assemblies
may be present for cutting tables longer than 40 feet.) Valves may be used to
concentrate the vacuum within a smaller portion of the table. The vacuum blower
assembly can be positioned either under the cutting table or at a remote location to
reduce noise in your workplace. Noise buffers can also be placed around the vacuum
blower.

Attached to the vacuum blower is a vacuum relief valve. This provides airflow to cool the
vacuum blower when the table surface is covered.
Note: To avoid
overheating
the blower, the
maximum vacuum
on the gauge should
not exceed 110
inches of water.

Use the installed air

relief valve to adjust
maximum vacuum
pressure.

Centrifugal Blower

Regenerative Blower

Cutting Surface
The cutting surface is constructed of a continuous flat sheet of polycarbonate plastic
(Lexan). Small diameter holes are evenly spaced over this surface. The free-floating
Lexan is placed over the “peak and valley” vinyl vacuum panel surface, which we call
a waffle. Allowing the Lexan cutting surface to float freely over the vacuum panels
eliminates problems that could be caused by thermal expansion. It also makes surface
replacement quick and simple.
Most cutting can be done using a rolling wheel blade on this Lexan surface. For very
detailed cutting or very tough materials, you can use a tangential knife blade on either
the Lexan, or on a felt or crumb rubber surface.

PatternSmith
PatternSmith is an integral part of the cutting system. It provides tools for pattern
creation, editing, and nesting, and then sends the correct cutting commands to the
controller. Please refer to the PatternSmith manual for more detail.
 2: System Operation
Before powering up the M4, make sure that:

1. Both the motor and signal cables are connected to the electronics cabinet and at
the carriage. Verify that all connections are secure.

2. The control computer and the electronics cabinet are connected to each
other through an Ethernet switch. (See Chapter 8, Establishing an Ethernet
Connection)

3. The compressed air is turned on and the air pressure is correct. Verify that the
air pressure is correct for each cutting device. With a sharp blade, most
materials can be cut with the cutting pressure set between 20 and 35 PSI. (For
more information, see Chapter 4.)
GLCD Keypad and Joystick
The screen you see on the GLCD depends on the state of the system. There are eight
possible modes: Startup, Local, Online (ready), Online (finished), Paused, Emergency
Stop, Out of Bounds, and Limit Detect.

Startup Mode

After you have first powered up, the only button available on the keypad will be “Find
Home.” At this point, the carriage is not necessarily at ‘Home’ position and not square
to the table, so you can’t proceed until you press the ‘Find Home’ button. During the
homing process, the carriage responds by slowly moving in the negative directions
along both the X- and Y-axes. When the carriage reaches the limit sensors, it
automatically squares itself to the table. Next, it aligns the cutting blade to zero degrees
and then moves to the Global (Hard) Home (0,0) position. At this point, it will switch to
‘Local’ mode.

During the homing process, the GLCD screen will update you by putting a check after
each axis that is completed.
Local Mode
In ‘Local’ mode, the joystick can be used and you can activate the pen, cutter, and
vacuum devices through toggles. The joystick has three speeds which increase with the
distance you move the joystick from neutral position.

Go Home:

Takes you back to Home position. The first time you press Go
Home, you will go back to the starting point for the last table you
cut (local origin for the previous table). The second time you
press it, you will return to global home (0,0).

Find Home:

Causes the carriage to find its limits again. It is seldom

necessary.

Pen and Cutting Device Toggles:

Raises and lowers pen and cutting devices.

Blade Change Toggle:

Positions the cutting head at Y=12”, a convenient position for

changing a blade.

Online Mode
The online modes for the GLCD are covered in Chapter 3, Plotting and Cutting.

Vacuum Blowers
The material you are cutting is held in place using vacuum
pressure over the table surface. Activate the vacuum blower(s)
from the magnetic starter located on the control panel.

Pause/ Restart/ Cancel

At any point in the cutting process, you can pause the carriage by pressing a Pause
Button, a large lighted orange mushroom button. There are two Pause Buttons, one on
each end of the carriage. When the carriage is in motion and under control of the host
computer, pressing the Pause button will immediately stop the carriage. The system will
remember where it stopped in the cutting process, retaining the information needed to
resume cutting if asked.
When the Pause Button is pressed, the following screen will be displayed.

You can choose to resume the cutting process, cancel the current cutting job, or change
blades before you continue. To resume cutting, simply press the Restart button. To
terminate the cutting job, press the Cancel button.

Restart Job:

This gives control back to the host computer to continue the current
cutting job. No action in PatternSmith is required.

Cancel Job:

This cancels the job just paused, sends a ‘Cancel’ message to the
host computer, and returns the cutting system to ‘Local’ mode.

Emergency Stop Mode

The Emergency Stop (E-stop) is the large red
button located on the right side of the Control
Console, at the origin end of the table. This is
available for emergencies such as a broken
blade or an obstruction on the table. A motor
or sensor malfunction will automatically
trigger an E-Stop.
When the E-Stop button is pressed, all position information is lost. Turn off the power to
the cutter and reset the E-Stop button by turning it clockwise until it stops and pops out.
Wait 15 seconds before turning the power on again. After you power up the cutter, you
will be able to resume cutting as usual.

Only use the E-Stop when absolutely necessary. In most cases, Pause is sufficient.
 3: Plotting and Cutting

Startup
Turn on power to the cutting system at the on/off switch located on the control panel.

Start PatternSmith and open the patterns or

project you wish to cut. Patterns are displayed in
the top portion of the screen, while nested copies
are displayed in the lower portion. You will find
complete instructions for using PatternSmith in the
PatternSmith User Manual.

Vacuum Hold-Down
Roll your material onto the vacuum table, smoothing out wrinkles as much as possible.
Make sure that all the holes on the surface of the vacuum table are covered by the
material. If your material doesn’t cover all of the holes, use a filler material to cover any
open holes. Porous material must be covered with a plastic sheet so the vacuum can
hold it firmly in place.

With your material in place, turn on the vacuum blower. The vacuum pressure gauge
on the end of the manifold should read at least 30” of water. When all of the holes in the
surface are sealed completely, vacuum pressure can rise to over 100”, however you can
cut successfully with pressure as low as 25”.

Cutting a Table
Local Origin
You can choose to start your cut job from the global home position (0,0) or from any
other location on the table. Use the joystick to jog the pen to the position where you
wish to start. Wherever the pen is located when you press Start is considered the Local
Origin. The Local Origin corresponds to the lower left hand corner of the PatternSmith
nesting view. If you try to start from a position that would not allow the entire job to fit on
the table, you will see the Out of Bounds screen below. In that case, cancel, jog to a
legal start point, and restart the job.

Plot Current Table Cutting Process

Slideshow

In PatternSmith, clicking Plot > Plot Current Table (Shortcut F10 key) will send the
table currently shown in the Nesting view to the cutter and start the cutting process.

When you initiate a cutting job from PatternSmith,

the GLCD will shift into Online (Ready) mode. The
action buttons available are ‘Start’ and ‘Cancel’.
The joystick is still active, so jogging is allowed.
You will be notified if you jog to a start point that
would cause an Out of Bounds error.
The information boxes show the material name and width, along with table number,
and the speed controls in place. The four icons at the bottom display the status of plot
options ‘Home when Finished’, ‘Cutoff left or right’, ‘Framing’, and ‘Pause after Pen’.
These are only for information. If you want to change any plot options, that must be
done in “Plotter Setup’ in PatternSmith.

Start Job:
This gives control to the host computer to send the commands for
the current table.

Cancel Job:
This cancels the job just started, sends a ‘Cancel’ message to the
host computer, and returns to ‘Local’ mode.

When the current table is finished, the GLCD will be in Online (Finished) mode. At this
point, you can press ‘Repeat Last Table’ to cut the same table again, press ‘Start Next
Table’ to advance to the next nested table in sequence, or press ‘Cancel’ to return to
Local mode. The joystick is again active, so jogging is allowed.

Cancel:
Pressing ‘Cancel’ sends a Cancel message to the host computer
and returns to ‘Local’ mode.

Repeat Last Table:

This tells PatternSmith to get ready to resend the table
just completed. It returns you to ‘Online (Ready)’ mode.
 Start Next Table:
This tells PatternSmith to get ready to send the next
table in your nested sequence. It returns you to ‘Online
(Ready)’ mode.

Plot All Tables

In addition to Plot Current Table, PatternSmith can also plot all tables for each material
in the project. Complete instructions can be found in the PatternSmith manual.

Limit Detect Mode

If any limit sensor is triggered by the carriage or other means, motion will be quickly
stopped. The information box will display which limit sensor was triggered. All position
information will be lost, so you will need to restart the cutter. The ‘Disable Motors’
button is for convenience so that you can move the carriage to the origin by hand before
restarting.
 4: Plotting and Cutting Devices

Blades and Blade Holders

The M4 has two steered blade holders. Each holder can accept a rolling circular blade,
a knife blade, a notching blade, or a hole punch. The type of blade you use will depend
on the material and patterns to be cut.

Many materials can be cut successfully with the rolling blade. Tougher materials or
intricate patterns will usually require one of the knife blades. When cutting a new
material, test it with both cutting devices to determine which will provide the best results.

Rolling Blades
Rolling blades function by pinching the material between a sharp blade and a hard cut-
ting surface. They are best for cutting materials that are soft, flexible, and easily cut. To
avoid needless damage to the cutting surface, set your cutting pressure carefully to the
lowest value that will cut the material.

The minimum radius of curvature that you can cut successfully with a rolling blade is
about equal to the radius of the blade. If you need to cut very intricate patterns or tough
materials, try one of the knife blades.

Carbide 28 mm
This is a workhorse tool for thin materials. It is can be resharpened and is suitable for
heavy-duty cutting.

Changing the
Carbide Blade
Slideshow
Olfa 28mm
These are general-purpose rolling blades manufactured by Olfa. They are particularly
suited to cottons and vinyls, and for cutting multiple layers of material.

Changing the
Olfa Blade
Slideshow

Olfa 45mm & 60 mm

These are excellent for thicker materials such as insulation.
Knife Blades
Knife blades cut with a slicing action. Knife blade holders include an adjustable depth
shoe that rides on the surface of the material being cut. Adjust the blade depth to be
just slightly more than the thickness of material you are cutting. This is done by rotating
the shoe on the holder until you have the right blade depth, then tightening the clamp on
the shoe. You need enough cutting pressure to prevent the blade from riding up over
the material to be cut.

Knife blades are excellent when cutting tough materials and intricate patterns with a
tight radius. Soft, weak materials will flex too much from the cutting force of a straight
knife, and are usually best cut with rolling blades.

Carbide Knife Blades

Carbide knife blades are perfect for cutting thin but tough materials or intricate patterns.
Carbide blades give you a very long life, up to a month per blade. Standard blade
angles are 40°, 50° and 60°. The carbide blades are best for materials less than 1/8”
thick.

Changing the
Carbide Knife
Blade Slideshow
X-acto Blades
The X-acto holder uses a thinner blade, which makes it better for thicker materials. The
blade life is much less than that of a carbide blade, but the cost per blade is also very
low. The X-acto blade holder works with blade numbers 19 and 24. With the #24 blade,
you will be able to cut up to 0.40” materials.

Changing the
X-acto Blade
Slideshow

Graphics Blades
These tiny blades are perfect for cutting very intricate pattern designs. They can cut
holes as small as 1/16” and are ideal for kiss-cutting on sign vinyl for graphics.

Changing
the Graphics
Blade
Slideshow
Specialty Blades
The specialty blades can only be attached to Device 2.

Notch Tool
The Notch Tool is ideal for accurate slit or V-notching with no overcut. This only works
when you have used the notch element feature in PatternSmith to create notches. You
also need to tell PatternSmith that you have a notch tool available on one device (Plot >
Plotter Setup > Devices Tab).

The notch blade is mounted in the same

style blade holder as the carbide knife
blade. Replace the notch blade in the
same way that you replace the carbide
knife.

Rotary Hole Punch

Changing the
Rotary Hole
Punch Slideshow

The Rotary Hole Punch can quickly and cleanly punch small-diameter holes (1/16” -
5/32”) in thin materials. For thicker materials, you may need the optional Air Drill.
Attaching Blade Holders
Always attach cutting tools from the operator side of the carriage, as shown. This is
important because the knife blades must be attached facing toward the far end of the
table.

Cutting Pressure
The cutting pressure adjustments are located on the table control panel. With a sharp
blade, most materials can be cut with the cutting pressure set between 20 and 35 PSI.
Tougher materials may require up to 40 PSI. As the blade gets dull, you will need to
increase the pressure. When the pressure approaches 50 PSI, it is time to replace your
blade.
Pens and Pen Holders
The M4 features a pen holder that can accept most pens, up to one half inch (0.5”) in
diameter. Different size pens will require a different bottom tip to be screwed into the
barrel and may require a different size collet at the top.

The flow rates of different pens can vary considerably. Plotting speed is limited by the
flow rate of the pen being used. Typical plotting speed is 15-30” per second. Autometrix
recommends Fisher Space Pens for reliability and the most consistent flow.

Changing
the Pen
Slideshow
PatternSmith Settings
PatternSmith needs to know what tools you are using. In PatternSmith, click on Plot >
Plotter Setup and then go to the Devices tab.

Set the number of plotting or cutting devices in the Total Devices Selector box. For each
device, select the blade type that you are using. For the pen, your choices are Pen or
Dot Marker. For the cutting devices, the choices are Rolling Blade, Tangential Blade,
Notch Tool, and Rotary Punch.
 5: Maintenance

The M4 maintenance schedule is simple and, if followed, will ensure that your system
provides you with many years of trouble-free operation.

The most important part of maintenance is to keep the carriage, X and Y rails,
rack, sensors, and pinions clean and free from any debris.

Precautions
Turn off power to the system before doing any maintenance.

Never stand on the vacuum table top.

Keep material rolls off of the cutting table when the carriage is moving. If the carriage
hits a roll of material (or other object), this can cause extensive damage.

Keep scrap or waste material from getting caught along the sides of the carriage or
in the X-axis e-chain. Anything (material, plastic coverings, tape, etc.) that comes
between the extrusions and the moving carriage may cause damage to the system.

Keep all heavy equipment and supplies (forklifts, hoists, rolls of material, pallets,
etc.) away from the table. Bumping the table with force could cause it to lose
calibration or to sustain severe damage.

Protect the machine and yourself from static discharge with static mats and straps.
Always ground yourself before you handle electronic components.

Maintenance Note
If the machine starts making an unusual noise, try to determine the source of the
noise. This may be the first warning sign of a worn or damaged part. Replacing the
part or returning it to Autometrix for repair may prevent additional damage. Regular
maintenance reduces down time and allows you to schedule that down time.
Maintenance Schedule

Daily (every 8 hours of use)

•  Clean X-axis rails. Debris will interfere with the system’s performance.

•  Clean X-axis rack. Buildup of debris will cause premature wear on pinions.

•  Clean Y-axis linear rail. Accumulated dust will cause unnecessary wear.
Check cutting blade for wear. Dull or damaged blades reduce cutting
efficiency and may cause unnecessary wear to the cutting surface.

•  Check e-chain for material or obstructions. These can cause severe

damage to cables and carriage.

•  Clean the cutting surface by blowing it off with compressed air. This will
help maintain vacuum pressure.

Weekly (every 40 hours of use)

•  Check e-chain for debris, damaged cables, or overly twisted wires that can
cause system down time.

•  Wipe the X and Y-axis linear rails down with a drop of 3-in-1 oil on a soft
cloth.

•  Spray a very small amount of Triflow lubricant on each pinion. Jog both the
X and Y axes to their limits to spread the lubricant. Wipe off any excess.

•  Replace cutting blade. Sharp blades maximize cutting efficiency.

Monthly (every 160 hours of use)
•  Check blade bolt. The blade should feel rigid, with no blade wobble.

•  Inspect Olfa blade holder, if applicable. Blade should not move from side to
side. If it does, replace the blade holder.

•  Check X and Y-axis pinion gears. Pinion wear will affect the system’s
accuracy of movement. Adjust pinion engagement, if necessary, following
instructions below.

•  Clean system by using compressed air to blow dust, lint, and material out of
the carriage.

•  Clear the cutting surface holes by blowing them with compressed air. This
will ensure good vacuum pressure.

•  Using compressed air, blow the dust out of the electronics cabinet.

Annually (every 2000 hours of use)

•  Replace the rolling blade holder’s bolt. Prolonged use may cause the blade
to wobble and result in inaccurate cutting.

•  Grease vacuum blowers, following the manufacturer’s instructions.

•  Rotate or flip the cutting surface, as needed.

•  Adjust X-axis carriage trucks and pinions, following the instructions below.

•  Check the electrical connections to the vacuum blower magnetic starter.

Every Two Years (or more)

•  Replace Lexan cutting surface.

•  Replace and adjust X-axis and Y-axis pinion gears, using instructions that
follow.
Adjustment Instructions
Adjusting Support Bearings
We recommend that you remove the carriage once each year and clean and adjust the
support bearings.

Support Bearings
Adjustment Slideshow

Pinions
Pinion gears are wearable parts and must be replaced from time to time. Part of the
replacement process involves adjusting the backlash of the gear on the rack.

Lubrication:
The longevity of the pinion gears can be greatly increased by occasional lubrication
with Tri-flow. Apply lubricant to the pinion gear with a small brush. Be sure to apply
lubricant around the entire circumference of the pinion gear.

The pinion gears are clamped to the motor shaft with a clamping collar. When this
collar is loose, the pinion gear can be removed and replaced.

The X and Y-axis motors are mounted on eccentric motor mounts. These enable us
to adjust the motor engagement by simply rotating the motor. Rotating the motors
clockwise raises the pinion, decreasing backlash. Rotating them counterclockwise
lowers the pinion increasing backlash. The goal is to have almost zero backlash
without the pinion being too tight. This ensures the accuracy of the cutting machine
and reduces wear on the pinion gears.

Adjustment Replacement
Slideshow Slideshow
Cutting Head
If the cutting head is damaged, such as getting a bent air cylinder shaft, it will need to
be sent back to Autometrix for repair.

Removal Replacement
Slideshow Slideshow

Motors
You will need to remove and replace the X and Y motors in order to replace pinion gears
at least once every two years.

Removal Replacement
Slideshow Slideshow

Carriage
Removing the carriage from the table involves disconnecting the electrical lines and the
air hoses. Two people are needed to safely lift the carriage.

Removal
Slideshow

Before you replace the carriage on the table, you will need to:

•  Adjust the support bearings.

•  Replace the X-axis pinions.
•  Remove all cutting and plotting devices.

Replacement
Slideshow
 6: Calibration Guide
Each Advantage Radium system has configurable calibration settings that insure the
machine cuts accurately. These settings are configured when the machine is initially
installed, and under ordinary operating conditions should never change. The following
information is provided to give you written assistance, but please call Autometrix
customer service before you try to recalibrate. In most cases, the problem is
mechanical or electrical.

On a rare occasion, it is necessary to re-calibrate the machine if the calibration settings

are lost due to a significant power failure that causes your machine to lose part of its
flash memory. Also, if your cutting head or electronics cabinet has been replaced, you
may need to re-enter calibration settings.

USERCALS File
All calibration information is stored in flash memory on the controller. A backup is
also stored in a file on your hard drive called USERCALS. The controller calibration
information can be updated by sending the USERCALS file through Motion Mechanic.

Macro Based Calibration

Start Motion Mechanic (see Chapter 7, Using Motion Mechanic). Cover the first 200 cm
of your table with paper and turn on the vacuum blower.

Setting the X-axis Resolution

We have found that 200 cm is a convenient length for calibrating X resolution. Start the
process by typing:

200.0 XResolution

The calibration routine will report your current resolution value and prompt your next
actions. (Note: Your resolution value will be different from this example.)

> 200.0 XResolution

Current X Resolution is: -1698.5000
We will draw an X axis line 200.0000 cm long after you press any key
When you press any key on your computer keyboard, the cutter will draw a line and ask
you to measure and enter the line’s actual length.

Enter the line length in form: <linelength> xactual

Measure the length as carefully as possible, entering it using a decimal number (ex.
200.25 or 200.0) followed by ‘xactual’. Press enter and you will see something similar
to the following:

> 200.12 xactual

New X Resolution is: -1698.350
The machine will redraw the calibration line with an offset when you press any key.

When you press enter, the cutter will draw another line for you to measure, offset
1” from the first line. It should be the correct length. If not, repeat the X Resolution
process until the line length is correct.

Setting the Y-axis Resolution

We have found that 140 cm is a convenient length for calibrating Y resolution. Start the
process by typing:

140.0 YResolution

The calibration routine will report your current resolution value and prompt your next
actions. (Note: Your resolution value will be different from this example.)

> 140. YResolution

Current Y Resolution is: -1697.3500
We will draw a Y axis line 140.0000 cm long after you press any key

When you press a key, the cutter will draw a line and ask you to measure and enter the
line’s actual length.

Enter the line length in form: <linelength> yactual

Measure the length as carefully as possible, entering it using a decimal number (ex.
140.25 or 140.0) followed by ‘yactual’. Press enter and you will see something similar
to the following:
 > 140.12 yactual
New Y Resolution is: -1698.350
The machine will redraw the calibration line with an offset when you press any key.

When you press Enter, the cutter will draw another line for you to measure, offset
1” from the first line. It should be the correct length. If not, repeat the Y Resolution
process until the line length is correct.

Squaring the Carriage

We’re going to have the machine draw a square 140 cm on each side and draw the two
diagonals. When the diagonals are equal in length, your carriage is square to the table.

Start the process by typing:

140. SquareCarriage

The calibration routine will report your current offset value and prompt your next actions.
(Note: Your offset value will be different from this example.)

Current offset is: 0.0734

We will draw a square 140.0000 cm per side after you press any key.

When you press a key, the cutter will draw a square and its diagonals and ask you to
measure and enter the length of each diagonal.

Enter the length of the diagonal from top left to bottom right in form:
<diaglength> da
Measure the top left to bottom right diagonal as carefully as possible, entering it using a
decimal number (ex. 198.25 or 198.0), followed by ‘da’. Press Enter and you will be
prompted to enter the length of the top right to bottom left diagonal.

Enter the length of the diagonal from top right to bottom left in form:
<diaglength> db

Measure the top right to bottom left diagonal as carefully as possible, entering it using a
decimal number (ex. 198.25 or 198.0) followed by ‘db’. When you press Enter, you’ll
see the new offset value and the cutter will re-home itself.

New offset is: 0.0734

The machine will re-home now.

Repeat the “Squaring the Carriage” process until the diagonal lengths are equal.

Blade Angle Alignment

If you ever need your cutting head to be rebuilt, it will be recalibrated at the factory and
come back to you with a sticker on the Device 1 gear giving two new calibration values.
Open your USERCALS file in an editor such as WordPad or NotePad. You will see a
section like the following:

The second column in the USERCALS file above is the memory location. You will be
changing the values in locations 15 and 16. Enter the new calibration values found on
your Device 1 gear sticker into these locations. The top value on the sticker replaces
the number in Column 1 of location 15. The bottom value replaces the number in
Column 1 of location 16.

Save your USERCALS file. Open Motion Mechanic and send the USERCALS file to the
controller. (See Chapter 7 for detailed instructions.)
Retrieving USERCALS and MOPARAMS
To upload USERCALS values from the controller to Motion Mechanic type:

retrieve_usercals

To upload MOPARAMS values from the controller type:

retrieve_motion_params

Device Offsets
When you first install PatternSmith, you’ll need to enter the offsets from the pen location
to the cutting devices. There is a simple way to measure these.

• Press Go Home on your carriage to ensure your pen is at (0,0).

• Put a 4” strip of masking tape on the table under the pen and Device 1.
• Put another strip under Device 1 and Device 2.
• Put a punch on Device 1. Activate it to punch a circle in the tape under Device 1.
• Move the punch to Device 2 and activate it to punch a circle in the tape below
Device 2.
• Jog the machine until you can drop the pen into the center of the circle punched
with Device 1.
• Read the location off of the GLCD. That is the Device 1 offset.
• Jog again to drop the pen into the center of the circle punched with Device 2.
• Read the location off of the GLCD to get the Device 2 offset.
• (If you have an optional air drill, use the same technique.)
The theoretical values for the device offsets are shown in the diagram below.










These have to be entered in PatternSmith. Go to Plotter Setup and enter them as
shown below.

Measuring Device
Offsets Slideshow
 7: Troubleshooting Guide
Any problems you encounter usually fall into one of four distinct areas: Software,
Electrical or Firmware, Mechanical, or Vacuum.

If you encounter a problem, first write down all of your symptoms and the date when
the problem started. We will need as many details as possible. Even though you may
have a variety of symptoms that don’t seem related, the problem is usually caused by a
single component that is not functioning.

Many common problems are easy to solve or even avoid if you follow our
recommended maintenance procedures.

TroubleShooting Guidelines
Software:
The most common software problems involve communication errors. First, make sure
the Ethernet cable is plugged in. Then start the Machine Tools applet from the Control
Panel menu and test the IP address.

If you experience a system crash or a General Protection Fault error, go to the Control
Panel and disable Power Management. This resolves many software problems.

Electronics or Firmware:
The first step in solving apparent electrical or firmware problems is running our
diagnostic program, Motion Mechanic. The use of Motion Mechanic is explained later in
this chapter.

The most common controller problem is a loss of controller memory caused by a

power fluctuation or spike. If Motion Mechanic reports an “fsp” or “stack” error, reload
MOPARAMS and USERCALS as described later in this chapter.
Mechanical:
Most mechanical problems are easily avoided by good maintenance and by keeping the
system clean. Check for:

• debris (such as tape) in the rails

• dust or debris in support bearings
• badly worn or misadjusted pinions
• sticky device cylinders

Vacuum System:
The most common vacuum problems are caused by

• uncovered holes on the cutting surface

• a leak in the vacuum piping
• a clogged wire screen

Diagnostic Tools
There are a number of different tools you can use as you attempt to diagnose a
potential problem. Again, before using any of these tools and techniques, please
contact Autometrix Customer Service. We’ll walk through the process with you.
Controller LEDs
The status of the ESTOP and Pause, Motors Alarms, and Limit Sensors are all available
on the backplane inside the electronics cabinet.

The ESTOP and Pause lines are normally green, and change to off when triggered.
The motor alarms and limit sensors are also normally green and change to off when
triggered.

Using Motion Mechanic for Diagnostics

Motion Mechanic (MM) is a diagnostic tool that lets you communicate directly with the
controller of your cutting system. You can use Motion Mechanic for intercepting error
messages and for downloading init files and calibration files to the Controller. While Mo-
tion Mechanic is usually one of the first steps in solving apparent electrical or firmware
problems, we recommend that you only use it under the guidance of Autometrix Cus-
tomer Service.
Firmware locations:
The firmware for the M4 is divided into logical files as follows:

Low level firmware m3a447s4.bin

Init file M4_Init_100a.uc
Keypad file M4_KDM_100a.uc
Motion parameters M4_MOPARAMS
Calibration data M4_USERCALS

Each file must be downloaded to a specific location in the controller’s memory.

Starting Motion Mechanic:

Motion Mechanic was installed on your Control PC when your cutter was installed. You
can use the desktop icon to access Motion Mechanic, or you can open it from the Start
menu (All Programs > Machine Tools > Motion Mechanic). Before you open Motion
Mechanic, make sure that your cutter is turned on. When you open Motion Mechanic,
you first need to select your machine tool from the following dialog box. You may only
have one installed machine tool. Select your tool and click OK.
The Motion Mechanic Screen
The main screen in Motion Mechanic is used to relay messages to and from the
Controller. The first step in diagnosing a problem is usually to reboot the controller and
watch the incoming messages. In the dropdown box shown, select ‘Reboot – Load Init
File’ and then press Enter on your keyboard.

After you reboot, your screen should look like this.

Before you type anything in the MM window, you will need to turn on echo to see what
you type. You can do this by typing ‘batch_off’ or by pressing the F9 key. To stop the
echo, simply type ‘batch’. To be sure that your computer is communicating, you can
type ‘junk’ and press Enter. The controller should respond with a message ‘Error 2:
Token ‘junk’ not found’. (Error messages are shown in red.) If it doesn’t respond, your
computer is not communicating. Check your cables and then use Machine Tools (see
Chapter 8) to test the IP address.

The most common controller problem is a loss of controller memory due to a power
fluctuation or spike. If there is a report from Motion Mechanic or PatternSmith about
an “fsp” or “stack” error, we will help you reload the machine parameters from your
USERCALS and MOPARAMS files.

Sending and Storing Controller Files

The Send File button, found on the toolbar, allows you to send information in a file of
your choice to the Controller. Clicking this button opens a file selector box. Use this
selector to find and send MOPARAMS or USERCALS. These are the only files that can
be sent to the controller in this way. All others must be stored using the ‘Store’
command.

The Store file tool reloads your init files into the Controller’s memory. Use this button to
store an init file into a specific location of memory.
In the file selector box, first use the bottom dropdown menu (controller location) to select
the location to store the file on the controller. Your Autometrix Customer Service
representative will tell you what to do at this point.
Motor Drive Alarms
If a motor triggers an alarm, your system will automatically ESTOP, and you will get a
message on the GLCD keypad. Open the top of the electronics cabinet and look at the
drive alarms on the backplane. Then look at the LEDs on each drive to determine the
cause for the alarm.
 8: Establishing an Ethernet Connection
The M4 cutter is an Ethernet-enabled machine tool. This means that the Control PC
running PatternSmith must be connected to the M4 cutter through an Ethernet switch.

The M4’s IP address is always statically assigned, as it operates somewhat like a

server. The Control PC’s IP address will depend on whether it is also connected to an
existing network.

Host Computer IP Configuration

No Local Area Network Connection

If there is no existing network infrastructure, or the network does not have DHCP
services enabled, a static IP address must be assigned as follows:

1. From the Windows Control Panel, select ‘Network Connections’.

2. Right-click on the connection labeled ‘LAN Connection’ (or similar) and select
‘Properties’.
3. Select ‘Internet Protocol (TCP/IP)’ from the list of protocols and click ‘Properties’.
4. In the TCP/IP properties dialog, select ‘Use the following IP address’
5. Specify an IP address on the 192.168.1.0/24 network (192.168.1.x where ‘x’ is a
number between 1 and 254, and the subnet mask is 255.255.255.0). This is the
default subnet for Autometrix systems.
6. Click ‘OK’.
7. Reboot the computer if prompted to do so.
Connecting to an Existing LAN with DHCP Capability

When the Ethernet switch that connects the M4 to the Control PC also connects to an
existing network, the IP address and subnet information for both the M4 and its Control
PC must be configured to comply with the pre-existing network environment.
 1. From the Windows Control Panel, select ‘Network Connections’.
2. Right-click on the connection labeled ‘LAN Connection’ (or similar) and select
Properties.
3. Select ‘Internet Protocol (TCP/IP)’ from the list of protocols and click ‘Properties’.
4. In the TCP/IP properties dialog, select ‘Obtain IP address automatically’.
5. Click ‘OK’.
6. Reboot the computer if prompted to do so.

M4 Electronics IP Configuration
The M4 cutter will be configured at the factory with a static IP address on the
192.168.1.0/24 network (192.168.1.x where ‘x’ is a number between 1 and 254, and the
subnet mask is 255.255.255.0). If you are not connecting to a LAN, or if your LAN uses
that subnet, you do not need to change the IP address.

If you need to change the M4 IP address to work with your existing subnet, you must
first connect the Control PC through an Ethernet switch without connecting to the LAN,
and set its IP address statically on the 192.168.1.0/24 network. Change the IP address
of the M4 electronics as described in the next section. Then change the IP address of
your Control PC back to a dynamic assignment before connecting to your LAN.
.

Establishing the Machine Tool Ethernet Connection

First, install Motion Mechanic. This will also install a Machine Tools applet.

Make sure your cutter is turned on and connected to the Control PC through an
Ethernet switch.

Open the Machine Tools Properties applet (Start > All Programs > Machine Tools >
Machine Connections).

Click the ‘Add’ button

Make sure the ‘Don’t detect my machine tool’ checkbox is not checked.

Click ‘Next’. The Machine Tools applet will scan your networks and detect any machine
tools that are currently active.

In the next dialog, verify that your machine tool has been found.
Click ‘Finish’.

Back in the applet, select your machine tool, and click ‘Properties’. You can now
change the IP address of the M4 Cutting System.
9: Safety Precautions
This chapter is intended to make operators aware of potential hazards and to stress
the importance of safe equipment operation. We encourage everyone who operates
Autometrix equipment to use care to avoid injury and maintain a safe workplace.

Powered Mechanical
Cutting Head and Tools
•  Use caution when changing tools and blades as they are all sharp. Follow the
procedure in the manual and use hand protection if required at your location.
(Note: Wearing gloves is not recommended when operating CNC equipment.)

Machine in Motion and Pinch Points

•  You will be operating the cutter from the keypad location. Keep your free hand
away from the moving parts of the gantry in order to avoid potential pinch
points.

•  Never wear loose clothing that can become entangled when operating the
machine.

•  When the machine is in motion, stay clear and make sure others are clear. We
recommend a minimum clearance area of 1 meter from any moving parts
around the machine.

•  Never pick up cut parts while the machine is in motion.

•  We don’t recommend storing material rolls under the table. There is a risk that
they will interfere with the e-chain. You might also be tempted to access them
while the machine is moving.
Electrical Hazards
•  Turn off power before removing the top of the Electronics Cabinet. Follow your
local regulations when servicing electrical equipment (such as lock-out / tag-
out procedures).

•  Do not operate the cutter if you see that there is damage to wiring or
connectors.

•  Only use correct amperage fuses in the equipment.

Pneumatic Hazards
•  Do not alter the equipment supplied with the cutter.

•  Make sure the system is pressurized before powering on the cutter. Operating
the system without air pressure to the tools can cause damage to the tool
head, tools, markers, or surface.

Vacuum Hazards
•  Avoid getting contamination under the cutting surface or into dislodged
plumbing. This could seriously damage the blower or vacuum piping.

Racks (Material Handling Equipment)

•  Do not overload racks.

•  Use caution loading materials.

Parts

•  Use only Autometrix approved parts for repair and maintenance.

Mechanical Maintenance and General Precautions

•  When removing the gantry, turn off power. Support the gantry on stands or saw
horses, being careful not to let it fall over.

•  Do not stand on the vacuum table top.

•  Never leave a roll of material on the cutting surface where it could be hit by the
moving cutter.

•  Keep your workspace clear of clutter.

 10: System Setup and Requirements

Electrical Power Requirements

Host computer:
110-120 VAC, 20 Amp, Single (1) Phase for installations in the USA &
Canada. International requirements will vary.
Electronics:
North America: 110-120 VAC, 20 Amp, Single (1) Phase, dedicated circuit
Elsewhere: 208 / 220 / 235 / 240 VAC, 20 Amp, Single (1) Phase, dedi-
cated circuit
Vacuum blower(s)
208-230 VAC, 60 Amp, Three (3) Phase, dedicated circuit
-OR-
380 VAC, 40 Amp, Three (3) Phase, dedicated circuit
-OR-
440-460 VAC, 40 Amp, Three (3) Phase, dedicated circuit

The M4 electronics require single phase AC power, on its own 20 amp circuit, conduit
shielded, line conditioned, and surge protected. This power is supplied to a junction box
mounted at the origin end of the machine. In North America, 110-120 VAC service is
required. Outside of North America, higher voltage (208-240 VAC) is required.

The vacuum blowers use high voltage three phase AC power, on a dedicated circuit.
These circuits should be run in metal (shielded) conduit to a power disconnect (where
required by law), and then to the junction box on the blower enclosure.

Shielding Power Circuits

Care must be given to proper electrical routing and shielding. Shielding of power
circuits is required. Without the use of separate conduits and the separation of single-
and 3-phase power sources, signal interference may occur.

To avoid the possibility of signal interference due to stray electromagnetic fields, the
single phase power to the electronics cabinet and the 3-phase power to the magnetic
starters and vacuum blowers should be run in separate conduit and kept at least 12
inches (30 cm) apart. Whenever possible, avoid running power lines parallel to each
other. The single-phase and 3-phase power sources must always be separate circuits:
60-amp service for the 3-phase, and 20-amp service for the 110 and 220 VAC single-
phase.
Autometrix recommends line conditioning on the circuit that powers the electronics of
the cutting machine. This is particularly true if your facility’s power is known to fluctuate
or spike. For high voltage systems (208-240VAC), Autometrix recommends the Tripp
Lite LR2000 line conditioner and provides it as a standard part for systems sold outside
the United States.

Grounding Requirements
The braided grounding straps in each E-chain must be grounded to the table base.
Each X-axis rail and the screen between the cutting surface and vacuum panels must
also be grounded to the table. The table must be grounded to the building ground or a
ground rod or water pipe using minimum 4-gauge wire.

Compressed Air Requirements

The tools on the Autometrix systems are pneumatically actuated, so an air compressor
capable of sustaining 100-150 psi is required. A 15-20 gallon capacity tank is sufficient.
An oil-lubed compresser is usually quieter, but must be kept oiled. CFM is not as critical.
(5 CFM is sufficient.)