560 Sizer/Beveller OPERATORS MANUAL
5 6 0 S/B
Norfield
Effective S/N: Release Beta
Document Number 17-289
Beta Release: April 2006 First release
Norfield Industries P.O. Box 459 Chico CA, 95927 Technical Support: 530-891-4214 Parts: 800-824-6242
Serial No.: Date Sold:
Norfield Industries is the name that represents Quality, Reliability, Support, Innovation and True Customer Service. We have been dedicated to providing quality products and excellent customer service for more than 40 years. Norfield Industries has earned a reputation in the prehanging industry for setting standards for reliable machinery, full technical support, machine parts, full line industrial woodworking tools and supplies and a team of customer care representatives to support you! Our factory-trained technical personnel are ready to assist you on the telephone or in your shop.
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TABLE OF CONTENTS Safety.................................................................................................................................. 6 Introduction ....................................................................................................................... 9 Specifications ..................................................................................................................... 10 Section 1 Installation......................................................................................................... 12 Section 2 Operational Controls .......................................................................................... 18 Section 3 Adjustments ....................................................................................................... 36 Section 4 Maintenance....................................................................................................... 38 Consumables ......................................................................................................................... 42
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SAFETY
Safety considerations are an important element of machine installation and operation. Actively maintaining a safety mindset about yourself and others while working around or on the equipment is of primary importance. Operators and maintenance personnel should refer to the safety information on the following pages to familiarize themselves with warning labels and practices providing for safe operation and servicing of this machine.
Danger indicates an imminently hazardous situation, which if not avoided, WILL result in death or serious injury.
Warning indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. Caution indicates a potentially hazardous situation which, if not avoided MAY result in minor or moderate injury. It may also be used to alert against unsafe practices. Caution, without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided may result in property damage (i.e. not personal injury). Notice indicates important information that if not followed may CAUSE damage to the equipment.
Mandatory Action conveys an action step that should be taken to avoid the hazard.
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SAFETY
Do not operate this machine unless all guards are in place and working correctly. If any guards or hazard labels are missing or damaged call Norfield's Service department immediately and request a replacement at 800-824-6242. Read and understand the operator's manual before using this machine. Failure to follow proper operating instructions could result in death or serious injury.
This machine, when in operation, produces wood chips and dust. The operator and all persons in the work area MUST wear approved eye protection with permanently attached, rigid plastic side shields. These safety glasses must conform to ANSI Z87.1 standards and will have "Z87" printed on the lens. This machine, when in operation, produces a noise level greater than 85dB. The operator and all persons in the work area MUST wear approved hearing protection. OSHA has determined that a noise level in excess of 85dB average in 8 hours can cause permanent hearing damage. We recommend that hearing protection be worn even if the decibel level is below 85dBA. Certain types of wood dust can cause allergic reactions, Sawdust has been determined to be a Group A carcinogen by the International Agency for Research on Cancer (IARC). A dust collection system or an approved personal dust mask MUST be used during the operation of this equipment. This machine has moving parts that loose clothing and long hair can become entangled in. Take care not to become caught between the work material and the feed mechanisms or any other moving components. Before beginning any service repairs, general maintenance, or adjustments you MUST follow proper Lockout Tag-Out procedures. OSHA regulation 1910.147 establishes a minimal lockout tag-out procedure to assist employers in development of their own procedures. Only trained personal that have read and understand the operator's manual and all the safety precautions may operate this machine.
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SAFETY
Inspect the machine at the beginning and end of each shift for damaged or cracked components such as, but not limited to, saw blades, router bits, drill bits, and boring bits. Never leave this machine unattended while it is in operation. Make sure that all electrical and air is in the off position when the machine is not in use or is unattended and that any cutting blades have come to a complete stop. Do not attempt to clean material from this machine until all the cutting blades have come to a complete stop. Even when the machine has been turned to the off position it may take up to several minutes for the blades to coast-down to a complete stop. Woodworking machinery is inherently dangerous, common sense and good safety practices are your best defense against injury. If you have any questions regarding the correct operation of the machine and safety procedures in this manual call the Norfield Industries Service Department at 800-824-6242.
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INTRODUCTION Congratulations on your purchase of the new 560 Sizer/ Beveller . The 560 Sizer/ Beveller was designed and manufactured conforming to a set of rigid specifications by trained workers who take pride in the quality of their work. The 560 Sizer/ Beveller provides the most advanced industrial controlled technology for your wood and metal door production plant. Unlike current machines, the 560 Sizer/ Beveller utilizes Rockwell computer control and state-of –the-art touchscreen interface. The machine operator can change from a 3/16� undercut door to a 1/16� undercut or pass through mode with a simple touchscreen entry. Only the touch of a finger is needed, and no stop adjustments or cutter changes are required. This versatility is unmatched on any current production door-sizing machine and drastically reduces operator training and increases shop capacity and production efficiency. Most importantly, it increases your margin on every door unit produced. Each Norfield machine must pass a series of tests and inspections before it is released for shipment. In order that this machine may provide you with a long period of continuous and satisfactory service, it is necessary that it be properly installed, operated and maintained. This manual has been prepared to assist you in carrying out these functions. We urge you to study the contents of this manual and to be guided by the suggestions herein.
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SPECIFICATIONS Electrical Requirement AC Line Voltage
Phase
Hertz
Amperage
208
3
60
50
230
3
60
45
460
3
60
30
Air Requirements
7.4 CFM @90PSI 1/2” Air Supply
Machine Cycle Rate Shipping Weight Minimum Floor Space Requirement (Width x Length x Height) Vacuum Requirements
1900CFM thru 8” duct
Machine Capabilities Door Width
1’-0” to 4’-0” Max
Door Height
6’-6” to 8’-0” Max 1-3/8” to 2-1/4” Max
Door Thickness Raised Molding Height
3/4” Max
Molding Distance to Door Edge
3-3/4 Min.
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SECTION 1 INSTALLATION 1.1 SHIPPING DAMAGE & SHORTAGES Before and after the crated machine is unloaded from the truck the crate should be inspected for any signs of damage. If suspected damage is found it must be noted on the bill of lading and signed by the driver and the person receiving the shipment. After the machine has been uncrated inspect it and all other contents of the crate for shipping damage. In the event that damage has occurred in transit notify the freight carrier and Norfield Industries immediately. Inspect the complete shipment against the packing slip to make sure all items listed are accounted for. If any shortages are noticed, the freight carrier and Norfield Industries should be notified immediately. While any shortages, other than back orders, or freight damages are the complete responsibility of the freight carrier, Norfield Industries desires to be notified so that the replacement of lost or damaged parts can be expedited. 1.2 INSTALLATION The information in this section refers to the installation and setup of the Norfield 560 Sizer/ Beveler. Since the purchase of the machine includes a start-up by a field technician, the following five items MUST be accomplished before the technician arrives: 1.Uncrate the machine and inspect for shipping damage or shortages. 2.Position the machine in its permanent location 3.Provide the proper electrical supply and make all connections. 4.Provide the proper air supply and make connections. 5.Provide and connect the vacuum system. 1.3 LIFTING & MOVING THE MACHINE The electrical control panel and the machine center must be moved simultaneously to prevent damage to the control cabling. . Once the crate top and sides has been removed unbolt the angle brackets that connect the main frame of the Sizer to the shipping base. Remove the bolts that hold the electrical cabinet frame to the create base. Lift the electrical cabinet using the attachment point provided at the top of the frame. 1. Once the electrical control panel has been removed, attach the two leg bases to the control panel frame. 2. Center the forklift on the operators’ side of the machine. Leave enough space between the machine and the forklift to not damage any part of the machine.
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INSTALLATION 3. Fork extensions in good condition can be used to lift or move the machine. 4. After lifting, make sure that all four corners are off the ground and/or crate base before moving the machine. 5. When moving the electrical control panel be sure to use the lifting point provided.
V2
Vacuum Connection Point
Material Flow Figure 1-1
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INSTALLATION 1.4 AIR SUPPLY & CONNECTIONS Clean, dry air is important for the continued performance and low maintenance of air operated tools and equipment. Foreign materials such as moisture, dirt, grit, and pipe scale, all generally present in air systems, can cause severe abrasive wear in valves and cylinders. Before connecting the Horizon Sizer to your air supply, insure that you have adequate mainline filtration and drainage. In addition to adequate filtration, Norfield also highly recommends the use of an air drying system. If you have any questions regarding your air system, please contact Norfield Industries or consult with the Norfield service technician upon arrival for the start-up. The air supply is connected to the machine at the S.F.R. unit located under the electrical cabinet. See figure 1-2. The supply line should be 1/2 I.D. minimum if the length of the run is 75 feet or less. If the length of the run is between 100 and 300 feet, 3/4" I.D. pipe should be used. Use 1" I.D. pipe for runs between 300 and 1000 feet.
Figure 1-2
Never use a supply line less than 1/2� I.D. or and fittings to connect the air supply to the machine with less than a 3/8� inside Diameter.
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INSTALLATION 1.5 ELECTRICAL CONNECTIONS The 560 Sizer requires a 230-volt, three phase, 50-amp connection with a neutral and ground. A local electrician brings five wires to the machine from the load center. The load center is located on the back of the main electrical cabinet. Refer to Figure 1-3
Only a Qualified Electrician can make the electrical connection to the machine. Please refer to the Electrical Plate for the specific machine requirements
Figure 1-3
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INSTALLATION 1.6 POSITIONING THE MACHINE. Figure 1-4 shows a typical shop layout with the overall dimensions of a Door Machine line. This information is pertinent to positioning the Sizer in relation to the Door Machine and Loader. Clearances around the line depend on your specific shop layout and material handling needs. Contact a Norfield Field Application Engineer if you would like assistance determining your optimum shop layout.
Material Flow Figure 1-4
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SECTION 2 OPERATIONAL CONTROLS 2.1 OPERATOR CONTROLS Control Power The Control Power switch located on the main operators console turns on and off the electrical power to the system, and will stop all machine functions when turned off. Control power should be turned off if the machine is left unattended for extended periods of time. To resume normal operation after control power has been turned off, it will be necessary to re-home the machine. Emergency Stop Push Button Depressing any of the emergency Stop buttons on the machining center, door loader and the assembly center will stop all system functions. To return to normal operation clear the machine of any material and re-home the machine. 2.2 POWER UP PROCEDURE 1. The following procedure will guide you in powering up the machine for the first time. This procedure should be followed after any service work is preformed. 2. Make sure the Main Panel Doors are Closed. 3. Make sure the Main Electrical Breakers are switch on. 4. Turn on air shutoff valves. The pressure gauge should read 90 P.S.I. 5. Turn on electrical power to the main electrical panel.
O
is off and I is on.
6. Check Emergency Stop Buttons. Rotate knob to release the button. 7. Turn on keyed power switch. 8. At the Machine Start screen, select the Machine Start button, which will start the homing process of the Door Loader. 9. When the Door Loader has completed the homing process, the message display will say “The Machine is Ready”. 10. When the Sizer has completed it’s startup process the Sizer status will say “Not
Ready, Select a Machine Mode”
11. Select a machine mode for the Sizer.
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OPERATIONAL CONTROLS 2.3 THE OPERATOR SCREEN Main Operator Screen: This is the main operators control screen for the Sizer, and is displayed at system startup. See figure 2-1.
Figure 2-1
Loader & Sizer Status: Displays the operational status of the Loader and Sizer. Loader & Sizer Stop Buttons: Use the stop button to immediately pause any machine cycle. The Sizer gives you the option to either RESUME, or to ABORT the machine cycle after the stop button is pressed. Resume will continue the cycle where it had been stopped. Abort will keep the machine stopped where it is. Loader Screen: Touching the Loader Screen button will activate the loader operators command screen. Loader Service: Touching the Loader Service button will activate the loader service command functions. Sizer Screen: Touching the Sizer Screen will activate the Sizer operators command screen. Sizer Service: Touching the Sizer Service will activate the service commands functions.
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OPERATIONAL CONTROLS 2.4 SIZER OPERATIONS SCREEN The Sizer operations screen controls most of the machine functions and setting. See figure 2-2.
Figure 2-2
Machine Mode Control: Select either “Pass Thru” mode or “Size Bevel”. The machine will not function until one of the two modes have been chosen. Selecting “Pass Thru” mode will allow a door to pass through the machine without sizing or beveling the door. Selecting the “Size Bevel” mode will add a 3 degree bevel to the strike side of a door.
When a machine mode is selected the machine will start the homing process.
Door Feed Mode Control: During normal operation this will be set to “Auto”. This function allows the operator to manually feed doors through the machine • •
Manual Mode: When Manual door feed mode is selected the operator must touch the Feed Door button to feed a door from the Feeder Table onto the Sizer. Auto Mode: When Auto door feed mode is selected the door will feed automatically when the Sizer is set to the Auto Width mode, there is a door available on the Feeder Table, the Sizer is ready, and the Machining Center ready. The Auto Door Feed mode can not be used if the Starting Door Width is in the manual mode.
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OPERATIONAL CONTROLS Manual door feed button: This control is used to manually feed a door into the Sizer. Manual Mode: When the door feed mode is set to Manual the operator must touch this button to feed the door from the Feeder Table into the Sizer. The button will stay lit until the Sizer has completed its cycle, or at the end of 5 min. Which ever comes first. The button must be pressed again after each cycle of the Sizer. The door may not be processed immediately when the feed door button is pressed. The Sizer will only process a door when the Machining Center is ready.
CAUTION: Auto Mode: When the door feed mode is set to Auto this button will be lighted to indicate that the machine is in the Auto door feed mode and will feed a door automatically when the system is ready.
When the Sizer is set to a manual door width it is possible to feed a door into an incorrectly adjusted machine. Always check the door width setting before manually feeding a door.
Door Feed Rate Selector: This control is used to set the speed that the door will travel as it is being sized. When the Machine Mode in set to the Size Bevel mode the operator must select a Feed Rate. The Fast rate is used for small undercuts on softwoods when fast cycle times are desired. The Med rate is used for larger undercuts in softwood or for small undercuts on hardwoods when fast cycle times are desired. The Slow rate is used for large undercuts in hardwoods or when the best finish quality is desired. When the machine mode is set to Pass Thru mode the feed rate is automatically set. Undercut selector: This control is used to select the amount the door will be cut, under the Starting Door Width. When Std is selected the machine will undercut the door by the “standard” amount. The current “standard” undercut setting is displayed in the window below the selector buttons. To change the standard undercut setting refer to the instructions in the Sizer service section. When Spec is selected the door will be undercut by a “Special” amount. The current “Special” undercut setting is displayed in the window below the selector buttons. To change the special undercut setting touch the numeric display window below the selector buttons and a numeric entry pad will be displayed. See figure 2-3.
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OPERATIONAL CONTROLS Enter the desired undercut, to .25 inch maximum. By pressing the return button the undercut will be saved and then you will be returned to the Operators Screen. If an error is made, use the back space button and reenter the correct value. Use the backup button when the display is zero to return to the Operator Screen without changing setting.
Figure 2-3
Starting Door Width: This control is used to select the method used to set the width index. Auto Width: When the Starting Door Width is in the Auto mode the width index will automatically adjust to match the door on the Feeder Table. The door will be sized to the nearest book size, minus the undercut setting. See item 5 above for instructions concerning undercuts. The door width selected by the Sizer is displayed in the window below the buttons. The Auto Door Feed mode can not be used if the Starting Door Width is in the manual mode. When the Sizer is set to a manual door width it is possible to feed a door into an incorrectly adjusted machine. Always check the door width setting before manually feeding a door.
Manul Width: When the starting door width is in the Manual mode the width index is set manually. To change the door width press the window below the selector buttons and a numeric entry pad will be displayed. See Figure 2-4.
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OPERATIONAL CONTROLS
Figure 2-4
Enter the new door width setting. The value must be between 11.75� minimum to 48.25� maximum. By pressing the enter button the value entered will be saved to the new setting and you will be return to the operator screen. If an error is made press the backup button to delete the last number entered and enter the correct value. By pressing the backup button when the display is zero will return you to the Operator Screen without changing setting. The width that is entered here is the width of the door before it is sized. The finished dimension of the door will be this setting minus the undercut setting.
Return to Main Screen: This button is used to return to the Main Screen. Jump to Loader Screen: This button is used to jump to the Loader operator screen. Machine Status and Message display: This area is used to display machine status and warnings. Sizer Stop button: Use the stop button to immediately pause any machine cycle. The Sizer gives you the option to either RESUME, or to ABORT the machine cycle after the stop button is pressed. Resume will continue the cycle where it had been stopped. Abort will keep the machine stopped where it is. Using the stop button during the door sizing cycle will result in sanding wheel marks on the edge of the door that may be unacceptable.
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OPERATIONAL CONTROLS 2.5 SIZER SERVICE & DIAGNOSTICS
Figure 2-5
Mode Selector: This button is used to select between the Run Mode and the Service Mode. Run Mode: When the machine is in the Run Mode the machine will operate based on the selections made on the Sizer Operator Screen. When the machine is in Run Mode the menu options shown in figure 2-5, with the exception of Width Cal and Undercut Setup, can be used to monitor functions only and the operator can not change the status of any of the outputs or settings. To change the machine to the Service Mode the operator must first touch the Stop Sizer button, followed by the Abort button. This will allow the Sizer to go into the Service Mode. Service Mode: When the machine is in the Service Mode the menu options can be used to calibrate settings and test machine functions. To return to the Run Mode touch the Run Mode button.
Machine interlocks are disabled in service mode. Use extreme caution when making changes to setting and moving machine parts.
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OPERATIONAL CONTROLS
Returning to the Run Mode will reset all outputs to their normal state.
Sizer Screen Button: When the machine is in the Run Mode this button will return the touch screen to the Sizer Operator Screen. Fig. 3-5 Machine Status and Message display: This area is used to display machine status and warnings. Sizer Stop button: Use the stop button to immediately pause any machine cycle. The Sizer gives you the option to either RESUME, or to ABORT the machine cycle after the stop button is pressed. Resume will continue the cycle where it had been stopped. Abort will keep the machine stopped where it is. The Stop Sizer button is only active in the Run Mode. To stop the Sizer in Service Mode use the E-stop.
I/O Monitor: This button moves you to the Input Monitor Screen. The input monitor screen is used to verify the state of the inputs to the controller. See figure 2-6. The operator can not change the state of any of the inputs from this screen.
Figure 2-6
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OPERATIONAL CONTROLS Press the NEXT button to move to the Output Monitors 1 screen. See figure 2-7. The output monitor screens are used to verify the state of the output from the controller. The operator can not change the state of any of the outputs from this screen. Pressing the Sizer Service button will return to the Sizer Service & Diagnostics Screen.
Figure 2-7
Pressing the PREV button to return to the Input Monitors screen. Press the NEXT button to move to the Output Monitors screen 2. See figure 2-8. Press the Sizer Service button to return to the Sizer Service & Diagnostics Screen Touch the PREV button to return to the Output Monitors screen 1. Press the Sizer Service button to return to the Sizer Service & Diagnostics Screen.
Figure 2-8
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OPERATIONAL CONTROLS Crowd Rollers: This button moves you to the Crowd Over Roller Screen. See figure 2-9. The Crowd Over Rollers Screen is used to manually operate the crowd over rollers. These buttons are only active when the machine is in the service mode. → Pressure ON: Touch the Pressure ON button to turn the crowd cylinder air
pressure on. This button will then be highlighted and stay on. → Pressure OFF: Touch the Pressure OFF button to turn the crowd cylinder air
pressure off. This button will then be highlighted and stay on.
→ Crowd Door: With the air pressure on, touching the Crowd Door button will make
the crowd over rollers move. Releasing the button will allow the crowd over rollers to return to their normal position.
→ 2.4 Crowd Cyl Auto Sw: This in an input indicator that lets the operator know
when the crowd over cylinder has reached the end of its stroke.
Touch the Sizer Service button to return to the Sizer Service & Diagnostics Screen.
Figure 2-9
Width Index: This button moves you to the Width Index Control Screen. See figure 2-9. The width index screen is used to manually move the width index. These buttons are only active when the machine is in the service mode. When you enter this screen the width index motor will default to the Med speed. To change the speed, touch one of the other buttons.
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OPERATIONAL CONTROLS
Figure 2-10 → Jog Width Smaller: The Jog Width Smaller button is deactivated when there is a
door in the machine. Touch the Jog Width Smaller button to move the machine to a smaller width.
→ Jog Width Larger: Touch the Jog Width Larger button to move the machine to a
larger width. → Home: Touch the Home button to move the width index to the home position. → Reset Drive: Touch the Reset Drive button to reset any drive faults. If there is a
physical problem with the drive it must be corrected first. → 2.5 WI EOT IN: This is an indicator light that displays the state of the Width
Index in end of travel in sensor. When this light is off the width index is as small as it will go. → 2.6 WI Home Prox: This is an indicator light that displays the state of the Width
Index Home location sensor. When this light is off the width index is larger than the home position. When the light is on the width index is smaller than the home position. → 2.7 WI EOT OUT: This is an indicator light that displays the state of the Width
Index out end of travel out sensor. When this light is off the width index is as large as it will go.
→ 2.8 WI VFD Status: This is an indicator light that displays the state of the Width
Index variable frequency drive. The indicator is green when the drive is OK. The indicator flashes red when the drive is faulted. → Encoder Position: This area displays the position of the width index encoder.
Counts is the total number of counts the width index encoder has moved from the home position. Inches is the current width setting in inches.
→ Encoder Rate: When the width index is moving, this area indicates the speed that
the width index is moving.
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OPERATIONAL CONTROLS → WI Completed Cycles: This area displays the total number of times the width
index has moved.
Press the Sizer Service button to return to the Sizer Service & Diagnostics Screen.
Machine interlocks are disabled in service mode. Use extreme caution when changing the state of outputs.
Misc. Outputs: This button moves you to the Misc. Outputs Screen. See figure 2-11. The Misc. outputs screen is used to test the outputs that are not covered in another Service Screen. To test an output touch the button labeled with the output you want to test. The output should come on and stay on only when the button is being touched. Remove your finger from the button to return the output to its normal state. Touch the Sizer Service button to return to the Sizer Service & Diagnostics Screen.
Figure 2-11
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OPERATIONAL CONTROLS Power Feed. This button moves you to the Powerfeed Control Screen. See figure 212. The Power Feed System screen is used to manually operate the Power Feed System. These buttons are only active when the machine is in the service mode.
Figure 2-12
→ Air Cylinders: There are four buttons under the heading Air Cylinders. These
buttons control the air cylinders that raise and lower the power feed wheels. Touch the up buttons to raise the power feed wheels. The button will be highlighted and the power feed wheels will stay up until you touch the down button or you return to the run mode.
→ Drive Motors: There are six buttons under the heading Drive Motors. These
buttons control the speed and direction of the power feed motors. The four buttons to the left, labeled Slow, Med, Fast, and Pass Thru, control the speed that the power feed wheel will turn when activated from this screen. Pass Thru is the fastest speed. To select a speed, touch one of the buttons. It will be highlighted to show that it has been selected. To change your selection, touch another button. When you enter this screen the Drive Motors will default to the Pass Thru speed.
The two buttons to the right, labeled Fwd, and Rev, will start the power feed motors in either the Forward (normal operating direction) or Reverse, opposite of the normal direction. The power feed motors will turn only while the button is being touched. All four power feed motors will turn in the same direction and at the same speed.
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OPERATIONAL CONTROLS → Feed table Output Photoeye: This is an indicator light that displays the state of
the feed table output photo eye. When the light is off there is a door being transferred from the feed table to the sizer.
→ 2.0 Door On Infeed: This is an indicator light that displays the state of the door
on photo eye that is closest to the infeed end of the machine. When the light is off the photo eye is blocked. When the light is on the photo eye is clear. → 2.1 Door On Outfeed: This is an indicator light that displays the state of the door
on photo eye that is closest to the outfeed end of the machine. When the light is off the photo eye is blocked. When the light is on the photo eye is clear. → MC Infeed Photoeye: This is an indicator light that displays the state of the
Machining Center infeed photo eye. When the light is off there is a door being transferred from the Sizer to the Machining center.
Press the Sizer Service button to return to the Sizer Service & Diagnostics Screen. Width Cal.: This button moves you to the Width Index Calibration Screen. See figure 2-14. To access this screen the operator must first enter a password. See password screen. See figure 2-13. To recalibrate the width index touch the display window in the center of this screen and enter the desired value, the value must be between 11.75 and 48.25 inches.
Figure 2-13
Enter the actual door width, of the long side, of the last door cut and touch enter. Touch Accept and check that the displayed number is correct. The machine will calculate the new offset from the home position and recalibrate the width index. Touch the Accept button only once for each change. Touching the Accept button repeatedly will alter the calibration each time.
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OPERATIONAL CONTROLS
Figure 2-14
If the new offset from the home sensor is more then one inch, a message will be displayed. (Dimension Out of Range Please Try Again.) Check the dimension entered; if it is not correct enter the correct dimension. If the new offset needs to be more then one inch from the home sensor, it will be necessary to adjust the home sensor. Then, home the width index, and recalibrate the machine. Touch the Sizer Service button to return to the Sizer Service & Diagnostics Screen. Before testing the new width calibration it is recommended that the operator change from the Size Bevel Mode to the Pass Thru Mode and back to the Size Bevel Mode. This will force the width index to move and reset. Undercut Set up This button moves you to the Std. Undercut Setup Screen. See figure 2-15. The machine must be clear of doors to use this function. To access this screen the operator must first enter a password. This screen is used to reset the standard undercut the machine will use when sizing a door with the standard undercut selected. To change the standard undercut touch the display window in the center of this screen. A numeric entry screen will come up. Enter the new standard undercut dimension and touch enter. Touch the Sizer Service button to return to the Sizer Service & Diagnostics Screen.
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OPERATIONAL CONTROLS
Figure 2-15
Config screen: This button moves you to the Configuration Screen. This screen is used to configure the display unit. Do not change any of these settings, except under the direction of the Norfield Service Department. Alarms: This button moves you to the Active Alarms Screen. See figure 2-16. This screen displays all of the active alarms for the Sizer and the Loader. The up and down arrows allow the operator to scroll through the list if there are more then can be displayed on one screen.
Figure 2-16
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OPERATIONAL CONTROLS → Loader Alarm Reset: All button will reset all active Loader alarms. → Sizer Alarm Reset: All button will reset all active Sizer alarms. → Main: Returns to the Main Operators screen. → Alarm History: Returns to the Alarm History screen. → Loader Service: Moves to the Loader Service screen. → Sizer Service: Moves to the Sizer Service screen.
If the problem that caused the fault is not corrected the fault will reoccur. Pressing the Alarm History button to move to the alarm history screen. See figure 217. This screen displays the alarm history for the Sizer and the Loader. The up and down arrows allow the operator to scroll through the list if there are more then can be displayed on one screen.
Figure 2-17
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OPERATIONAL CONTROLS Alarm Banner: Figure 2-18 is the standard alarm banner. Whenever there is an alarm, this screen will come up over whatever screen is active. The text displayed in the banner will notify the operator of the current alarm. Refer to the troubleshooting section of this manual for explanation of the alarm codes. Pressing the OK button will clear the alarm and remove the banner, after the cause of the alarm has been removed.
Figure 2-18
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SECTION 3 ADJUSTMENTS 3.1 FLOW CONTROL VALVES The speed at which most of the cylinders on the machine extend or retract is controlled with flow control valves. They are normally mounted on both the front and rear ports of the cylinder they control. In some cases, however, they are mounted a short distance from the cylinder. Flow control valves allow air to pass unrestricted in one direction and with a regulated flow in the other. The way they are mounted on the cylinder allows the flow of air out of the cylinder to be controlled. When a cylinder extends, unrestricted air enters the rear port and forces the piston forward. As the piston moves, the air in the cylinder that is ahead of the piston is forced, as exhaust, out the front port. Likewise, when a cylinder retracts, unrestricted air enters the front port while the air behind the piston is forced out the rear port as exhaust. By regulating the flow of this exhausting air the speed at which the cylinder rod moves can be controlled. To adjust a flow control, loosen the jamb nut that secures the adjusting knob and turn the knob clockwise (in) to slow the cylinder or counterclockwise (out) to speed up the cylinder (increase the exhaust flow). Retighten the jamb nut.
If you think it is necessary to adjust a flow control, first check the assembly with the air OFF to make sure it moves freely and does not stick or bind.
Before making any adjustment to the machine, all electrical and pneumatic power sources must be Locked and Tagged Out.
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SECTION 4 MAINTENANCE Before beginning any service repairs, general maintenance, or adjustments you MUST follow proper Lockout Tag-Out procedures. OSHA regulation 1910.147 establishes a minimal lockout tag-out procedure to assist employers in development of their own procedures.
4.1 GENERAL MIANTENANCE Using an air hose, blow sawdust off entire machine 2-3 times daily. Pay special attention to all slide surfaces, lead screws, sensors, motors and belts. For lubrication use petroleum based oils on Slide Rod and Bearing surfaces. The best oils are lightweight spindle oils for speeds up to 100ft/min. Do not grease. It will take up the bearing's running clearance and increase friction. DO NOT USE TEFLON OR SILICONE BASED SPRAYS, OR PENETRATING LUBRICANTS SUCH AS WD40. Clean gears and gear racks on width index module daily. A good stiff brush is best, but an air hose is better than nothing. NEVER clean the slide rods with lacquer thinner, acetone, or any other solvent. DO NOT LUBRICATE GEAR RACKS! 4.2 CUTTING BITS Cutter Head blades will need to be sharp to provide a clean, smooth door edge. All blades need to be kept sharp at all times. Failure to do so will result in an unacceptable finish on the door and the use of additional electrical-current and shortened motor and bearing life. Replace cutter head blades with Norfield replacement blades only. This will ensure a correct fit as well as smooth, accurate door sizing.
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MAINTENANCE 4.3 FILTERS
The air filters on your machine are designed to further clean air that is not heavily laden with moisture or impurities. If excessive water or pipe scale, etc. is present in the air to the filters, the filters will clog up and pass through the excess water, etc. For this reason if you do not have an in-plant air cleaning system, we suggest you contact the Norfield Service Department or your local air system supplier for assistance in correcting this problem. Water present in air cylinders and valves will severely shorten their life, up to 90%! Check the air filters daily. The drain on the pre-filter (particulate) is automatic, but still needs to be checked daily to make sure it is “dumping” all the water. The particulate air filter will require cleaning at intervals dependent on the quantity of impurities in your air supply. The secondary filter (coalescing) is designed to remove very small impurities and oils from the air. This filter must be replaced when the element appears discolored or dirty. 4.3 CYLINDERS Note: Keep cylinder shafts clean to prevent excessive wear. As seals in all cylinders will take a “set” when not operating, cylinder manufacturers strongly recommend that all cylinders be cycled at least two times each morning before placing a door and jamb in the machine. This will allow the cylinder seals to regain natural sealing ability and will lengthen cylinder life considerably.
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MAINTENANCE 4.4 BEARINGS AND LEAD SCREW NUTS Inspect all bearings and lead screw nuts of the Horizon Door Sizer after 1500 cycles. Check for noise, play, and smoothness of operation. The bearings used on the cutter head and the sander shafts have been lifetime greased at the factory. No further lubrication is required. 4.5 LUBRICATION Use petroleum based oils. The best oils are lightweight spindle oils such as 3-in-1 oil. Avoid grease. It will take up the bearing's running clearance and increase friction. DO NOT USE TEFLON OR SILICONE BASED SPRAYS, OR PENETRATING LUBRICANTS SUCH AS WD40. 4.6 BREAK-IN The bearings will go through a break-in process at startup. This process transfers small amounts of liner material to the shaft. It is best to aid this process with lubrication such as 3-in-1 oil or lightweight spindle oil. This cleans the shaft for a good transfer. A small amount of powder will accumulate at the end of the stroke. If a black sticky film appears in the shaft, wipe clean and re-apply 3-in-1 oil or lightweight spindle oil. Note: Keeping slide rods clean will lengthen bushing life. Never clean the slid rods with lacquer thinner, acetone, or any other solvent. This will remove the transferred material, requiring another break-in process and shorten bushing life. Never use oil, graphite or silicone spray on the bushings of any assembly of your machine to “free” it up. Any foreign substance such as those above will remove the small amount of linear material applied during the “Break-in” period. Applying these types of substances will also collect fine sawdust and dirt particles that will tend to wear the bushings very quickly. If any assembly is binding, and you have kept the mechanisms clean, the problem is most likely that the parts have become misaligned.
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CONSUMABLES
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Phone: 800-824-6242
Web: www.norfield.com
Parts Replacement Policy The following will explain Norfield Industries policy for handling warranty claims. Our "Limited Warranty" is stated below for your reference. Our warranty covers the replacement of defective parts; however, the labor to replace the parts on the machine is not included. Upon notification of a warranty claim, Norfield will either refer the customer to a regional repair facility or replacement parts will be shipped from the factory. Parts shipped from the factory will be invoiced to the customer's account until the warranty claim is verified. To obtain verification, the defective parts must be returned to Norfield within thirty (30) days from the date of the claim for inspection. Before returning the defective parts, please contact Norfield to obtain a "Return Material Authorization Number". All parts manufactured by Norfield and found to be defective will be given appropriate credit. All parts not manufactured by Norfield are covered by their respective manufacturer's warranty and will be sent to the original manufacturer for credit. When, and if, credit is issued to Norfield, we will in turn issue credit to your account.
Limited Warranty Norfield warrants any and all such parts manufactured by them against defects in material or workmanship for a period of one-year from date of purchase. Norfield's liability under this warranty shall be limited to replacing free of charge, F.O.B. Chico, California, any parts proved to be defective within the period of the warranty. Norfield will not be responsible for transportation charges or consequential damages. Norfield will not in any case or under any circumstances be liable or responsible for any injuries to persons or property suffered as a result of the use or operation of the machine, or losses or costs resulting from any period of non-operation for any reason. Parts which are claimed to be defective, but show tangible evidence of abuse or negligence will not be replace on a no-charge basis. Norfield reserves the right, at its own discretion without notice and without making similar changes in machinery previously manufactured, to make changes in material, design, finish and/or specifications. Any changes, alteration or installation of additional equipment to this machine without first obtaining written consent from Norfield may void this warranty. Determination of the effect of any alteration on this warranty is left to the discretion of Norfield. Norfield makes no written or implied warranty with respect to electrical equipment, including motors or other purchased components used in the manufacture of the machine. All such parts are covered by their respective manufacturer's warranty. We do endeavor, at all times, to purchase only those components manufactured by responsible manufacturers which we have found to be reputable in their handling or warranties. Norfield expressly disclaim any warranty, expressed or implied, other than those which are expressly made in this limited warranty.