450 LINEAR STITCHER PARTS & OPERATORS MANUAL
EямАective S/N: LS 6014 Release: 4
Document Number: 17-316
First Release: June, 2007 Second Release: August, 2007 Third Release: October, 2007
2
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 pre hanging 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.
3
This Page is Intentionally Blank
4
TABLE OF CONTENTS Safety Lockout Procedures Specifications Installation Operation Operational Settings and Adjustments Troubleshooting Maintenance Parts Replacement Policy Limited Warranty Contact and Order Information Part and Assembly Schematics
7 11 13 14 16 17 25 27 28 28 29 30
5
This Page is Intentionally Blank
6
SAFETY
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 but 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.
7
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 85dB. 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 dusk mask MUST be used when operating 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 lockiout tag-out procedure to assist employers in the development of their own procedures.
Only trained personnel that have read and understand the operator’s manual and all the safety precautions may operate this machine.
8
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 coastdown 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
9
This Page is Intentionally Blank
10
LOCKOUT PROCEDURES
LOCKOUT PROCEDURES The following is an example of the minimum requirements for a lockout/tagout procedure. Norfield strongly recommends that your company establish its own written procdeure. OSHA Regulation 1910.147 establishes a minimal lockout/tagout procedure to assist employers in the development of their own Lockout Procedures
All employees will comply with these procedures. All equipment and/or circuits will be locked out to protect against accidental or inadvertent operation when such operation of the equipment and/or circuits could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating device bearing a lock. Lockout Responsibility The primary responsibility for the proper lockout of equipment and /or circuits on a maintenance or repair project belongs to the project Supervisor and/or Foreman. However, this does not alleviate any sub-contracted maintenance or repair personnel from insuring that proper lockout/tagout procedures are followed at all times. The Supervisor and/or Foreman will insure that each employee is properly instructed in the safety significance of lockout procedures. Preparation for Lock-Out of Circuits and Equipment In the following steps, when more than one individual is involved with the project and required to lock out the equipment and/or circuits, each employee will place their own personal lock on the energy isolating devices. A lock for each individual involved is the preferred method for locking out energy sources. If this not feasible, the designated individual to the work crew (e.g. the project Supervisor or Foreman) with complete knowledge of who is on the crew may be designated by the work crew as the individual responsible for carrying out all steps of the lockout procedure. That individual will inform the work crew when it is safe to work on the equipment and/or circuits. Additionally, the designated individual will not remove a crew lock until it has been verified that ALL individuals are clear. 1. Notify all aected employees and customers that a lockout is required and the reason for it. 2. If the equipment is in operation, after obtaining approval, shut it down by the normal stopping procedures.
11
LOCKOUT PROCEDURES
3. Operate the switch, valve or other energy isolating devices so that all energy sources (electrical, mechanical, pneumatic, hydraulic, etc.) are disconnected or isolated from the equipment and/or circuits. Stored energy, such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air/gas, steam or water pressure, etc., must also be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc. 4. All aected employees are then required to lockout the energy devices with their individual lock. 5. After insuring that no personnel are exposed and as a check on having disconnected the energy sources, operate the push button or other normal operation controls to make certain the equipment will not operate. In the event that electrical circuits have been locked out, insure that the circuits are de-energized by applying an appropriate voltage tester that itself has been tested on live circuits. Be sure to return all operating controls to the neutral position. The equipment and/or circuits are now locked out.
Restoring Equipment and/or Circuits to Service 1.
When the job is complete and the equipment or circuits are ready for testing or normal service, check the equipment and/or circuits to insure that no one is exposed.
2.
When the equipment and/or circuits are clear, remove all locks. The energy isolating devices may be operated to restore energy to the equipment and or circuits.
12
SPECIFICATIONS
SPECIFICATIONS Electrical Requirements AC Line Voltage
Phase
Hertz
Amperage
120 VAC
1
60
5
Air Requirements PSI
SCFM
Minimum Supply Pipe I.D.
120
6
1/2” I.D. minimum air line when less than 20 feet from compressor OR 3/4” I.D. minimum when more than 20 feet from compressor.
Machine Capabilities Feed Rate
60 FPM
Production Capacity
10 Pieces/Minute
Jamb Width
3-1/2” to 8”
Jamb Length
Infinite
Jamb Thickness
7/16” - 7/8”
Stop Width
1” to 2”
Stop Thickness
1/4” to 5/8”
Edge Reveal
1-7/16” and 1-13/16”
Staple Spacing
11-1/2” or Adjustable
Shipping Weight
Approx. 1170 Lbs
Minimum Floor Space Requirement Width - 7’-5” Length - 26’-4” Height - 8’-9”
13
INSTALLATION
INSTALLATION The following information should be read completely before any attempt is made to uncrate, install or operate the machine. Before operating the machine, the following 5 items need to be accomplished: 1.
Uncrate the machine and inspect for shipping damages or shortages.
2.
Position the machine in its permanent location.
3.
Provide the proper electrical supply and make connections.
4.
Provide the proper air supply and make connections.
5.
Provide material for set-up and adjustment of the machine. ALLOW 10' - 0" MINIMUM CLEARANCE IN BOTH DIRECTIONS FOR MATERIAL HANDLING
MATERIAL FLOW
3'-2 1/2"
8'-6"
4' - 0"
AIR CONNECTION (6 CFM @ 90 PSI)
14
ELECTRICAL CONNECTION (115 VAC - 5 AMP)
ALLOW 3' - 0" CLEARANCE ON BOTH SIDES OF MACHINE
INSTALLATION
UNCRATING AND POSITIONING THE MACHINE: The shipping crate for the 450 is made up of a rigid wood base to which the machine is secured. A protective plastic cover and wood framework surround the machine. Also, a box containing small components and spare parts is usually enclosed in the crate. Before uncrating and positioning the machine, study the installation drawing on the previous page. Make sure that adequate clearance for material handling and machine access are provided. To uncrate the machine, the following procedure is recommended: 1. 2. 3.
Remove the wood framework and plastic covering. With the machine still on the base, move it close as possible to its permanent location. Rollers can be placed under the crate base that it can be moved into position easily. Remove the bolts securing the machine to the base and lift the machine into position.
SHIPPING DAMAGE AND SHORTAGES: After the machine has been uncrated, inspect the entire machine and all other contents in the crate for shipping damage. In the event there was damage in transit, notify the freight carrier and Norfield immediately. While any shortages or freight damages are the responsibility of the carrier, Norfield desires to be notified as soon as possible so that the replacement of lost or damaged parts can be expedited.
AIR SUPPLY AND CONNECTIONS: The 450 requires 6 CFM of clean, dry air for proper operation. The air supply is connected to the machine at the filter-regulator-lubricator (FRL) unit located on the lower frame channel. The supply line should be 1/2” minimum if the length of the run is 100’ or less. For runs between 100’ and 300’, a 1” supply line is recommended. For convenience, a quick disconnect at the connection point and an air shut-off valve the machine is recommended.
ELECTRICAL SUPPLY AND CONNECTIONS: The 450 requires an electrical input of 115 VAC @ 5 amps. It is equipped with a standard 3 prong 115 volt cord for easy connection. If an extension cord is used, 14 gauge is recommended as a minimum. If you prefer, the machine can be wired directly. To do so, remove the cord from the electrical control box and connect the supply to the same terminals. Either way, take care to keep the power cord clear of the operator and material movement. It is recommended that an electrical disconnect be provided near the machine for disconnecting all power from the machine when maintenance or adjustments are performed.
15
OPERATION
OPERATION For optimal safe operation of the 450 Linear Stitcher, follow the procedure listed below: 1.
Insure that the machine has the proper electrical and air connections (Installation, pages 14 - 15).
2.
Make sure that the machine is setup for your material specifications (Settings and Adjustments, pages 17-24)
3.
Turn the power ON by pulling out on the RED MUSHROOM KNOB located in the center of the control panel. This will start the motor for the drive wheels and supply power for the gun firing and power feed control systems. This button should be left ON as long as the machine is being operated.
4.
Insert a jamb face up and head end in first into the machine and make sure it contacts the appropriate reference stop.
5.
Insert a stop into the machine on top of the jamb. Make sure it contacts the appropriate reference stop.
6.
Push the GREEN CYCLE START push button that corresponds to the side your jamb and stop are on. The left button starts the right side and the right button, the left side. The machine may also be cycled by stepping on the appropriate foot switch.
7.
To achieve optimum performance from the machine, insert another jamb and stop on the opposite side and start its cycle.
JAMB AND STOP REFERENCE BOLTS
CYCLE START AND POWER BUTTONS
16
SETTINGS & ADJUSTMENTS
OPERATIONAL SETTINGS & ADJUSTMENTS CAUTION: DISCONNECT ALL ELECTRICAL POWER AND AIR TO THE MACHINE BEFORE MAKING ANY ADJUSTMENTS
REGULATOR AND LUBRICATOR ADJUSTMENT: Two FRL units (Filter-Regulator-Lubricator) are provided on the 450 to filter and lubricate the compressed air before it reaches the machine’s pneumatic components. They are both mounted on the lower frame channel of the machine for protection and accessibility. One is used to control the air for the drive and clamping system and the other is used for the staple guns / nailers only.
FRL FOR DRIVE AND CLAMPING VALVES AND CYLINDERS FRL FOR STAPLERS / NAIL GUNS (LUBRICATED GUN CONFIGURATION)
REGULATOR SETTING: The two FRL’s are independent of one another. The drive system regulator pressure should remain constant and is usually set at 90 PSI. The stapler / nail gun setting will vary depending on the gun type and material being run. It is usually set somewhere between 90 and 120 PSI. To adjust the settings on either regulator, pull the adjusting knob down (out) to unlock it, turn the knob either direction to increase or decrease the pressure then push the knob back in to re-lock the setting.
LUBRICATOR SETTING: Set both drop type lubricators so that one drop of oil is mixed with the air supply every 20 - 25 complete machine cycles. Adjustment is accomplished with the small adjustment screws recessed into the top of the lubricators. Turning the screw “out” will increase the oil drip rate. If the oil drip rate is too high, excessive oil will be visible at the exhaust ports of the control valves or the exhaust ports of the air tools. Observe the oil drip rate through the sight bulb on the top of the lubricator. Keep the lubricator filled with 10wt turbine oil. Note: machines equipped with oil less air tools (non-lubricated) will have only one lubricator.
17
SETTINGS & ADJUSTMENTS
FLOW CONTROL VALVES: EXTENSION SPEED CONTROL
RETRACTION SPEED CONTROL
The speed at which the air cylinders on the machine extend or retract is controlled by flow control valves. They are normally mounted on both the front and rear ports of the cylinder. Flow control valves allow air to pass unrestricted in one direction and with a controlled flow in the other. The way they are mounted on the cylinder allows the flow of air OUT of the cylinder (exhaust) to be controlled. To control the retraction speed, adjust the flow control on the rear or base of the cylinder. To control the extension speed, adjust the flow control on the nose or rod end of the cylinder. Before making an adjustment, loosen the nut on the adjusting knob. Re-tighten the nut (finger tight) to lock-in the setting after an adjustment has been made.
STAPLE / NAIL FIRING AND SPACING: Staple / nail gun firing and spacing are both controlled by a Programmable Logic Controller (PLC) which is located in the electrical cabinet. When a jamb is inserted into the machine, a photo-eye is blocked which tells the PLC that a jamb is present. When the Cycle Start button is pressed, the first staple is fired and a timing sequence begins which fires a staple / nail every .8 seconds as long as the material is still detected. When the end of the jamb clears the photo-eye and it “sees” itself again, a last staple / nail is fired and the timing sequence ends. With this system, there is very little in the way of adjustments that the operator need to make. There are, however a few things that the operator should be aware of: 1.
The distance from the top of the jamb to the first staple / nail is determined by the location of the jamb in relation to the staple / nail gun when the firing sequence is started. The effective length of the stop bolts on the stop arm can be changed if this distance needs to be changed.
2.
The distance between the first and second staple / nail is controlled by the speed at which the first powerfeed wheel travels UP to engage the jamb and start it moving. For optimum results, the flow control valves on the powerfeed cylinders should be adjusted so that the distance between the first and second staple / nail is 10 to 10-1/2”.
3.
The firing of the last staple / nail can be turned ON and OFF with the top toggle switch located on he side of the electrical cabinet. If a last staple / nail is not required, turn the toggle switch OFF (down position).
18
SETTINGS & ADJUSTMENTS
LAST STAPLE / NAIL TOGGLESWITCH
STAPLE / NAIL SPACING TOGGLE SWITCH
PROGRAMMABLE LOGIC CONTROLLER (PLC)
4.
5.
The bottom toggle switch on the side of the electrical box will switch the PLC to a mode that allows the operator to adjust the time between staple firings thus the distance between staples. To make this adjustment, remove the cover from the electrical box, open the small door on the controller and turn the small recessed screws clockwise to increase the distance between staples or counter-clockwise to decrease it. The screw designated “0” is for the left-hand gun and the one designated “1” is for the right -hand gun. As long as the bottom toggle switch is ON (up), this setting will be used by the controller. NOTE: Use care when making this adjustment. Only a slight amount of rotation is required to change the timer value. Rotation past the adjustment screws limits will damage the PLC.
STAPLE / NAIL DEPTH ADJUSTMENT: The initial adjustment of the “set” or “countersink” of the fastener is pre-set at the factory. Through time, future adjustments may become necessary due to conditions realtive to normal use of the machine. If adjustments are necessary, the following procedures should be followed.
GUN NOSE TO ROLLER DISTANCE DEPTH ADJUSTER
(Text on Next Page) ROLLER BRACKET HEX BOLTS
REFERENCE ROLLERS
NOSE TO ROLLER DISTANCE
19
SETTINGS & ADJUSTMENTS
GUN NOSE TO ROLLER DISTANCE (Continued)
The distance from the Reference Rollers (the surface of the stop material) to the nose of the gun is the primary adjustment to control the depth of the fastener. The closer the gun is to the material when it fires, the deeper the “set” or “countersink”. To reestablish the correct nose to roller relationship, loosen the two hex bolts that secure the roller bracket so that the nuts on the depth adjuster can be repositioned. Judging by the previous fastener depths, increase or decrease the nose to roller distance. Tighten everything back down and run a test stop and jamb.
RECOIL ADJUSTMENT: Recoil adjustment controls the length of time that the driver stays extended and remains in contact with the staple or nail. A long duration contact will drive the fastener deeper than a contact of short duration. The recoil is adjusted using the flow control valves on the gun firing valves located on both sides of the machine. Close down the flow control valves (clockwise) to kick the guns back slower and in turn create a long fastener/driver contact duration and a deeper countersink. Open the flow controls (counter-clockwise) to kick the guns back quicker for a shorter driver/fastener contact and a shallower set. Opening the flow controls is also the action taken to eliminate driver drag (the driver stays extended and mars the stop material). Recoil adjustment is extremely important and should be done carefully and patiently. It should be noted that the Nose to Roller and Recoil adjustments are interactive. Changing one will affect the other. GUN CUSHIONING FLOW CONTROL
GUN RECOIL FLOW CONTROL
LEFT HAND GUN FIRING VALVE
GUN CUSHIONING: Cushioning the guns as they return to their firing position prevents unnecessary wear and tear to the guns and machine. Cushioning is changed by adjusting the flow controls located on the recoil cylinders. Closing the flow control (clockwise) causes the guns to return slower. Opening (counter-clockwise), faster. Optimum adjustment is when the guns fall back at a smooth, uniform speed yet fast enough to be in position to fire the next staple.
20
SETTINGS & ADJUSTMENTS
REFERENCE STOPS: The Model 450 Stitcher features a Quick Change Stop System that allows quick changeover between leg and head jambs and between mitered and square stop material. This stop system also provides for “dedicated” setups for accuracy and reduced setup time. To change between one stop and another, use a 3/16 hex key (allen wrench) in the cam lock and rotate 1/4 turn counterclockwise to remove the stop arm. Install a new stop arm and rotate the cam lock clockwise to lock the stop arm in place. RETRACT SPEED CONTROL
EXTEND SPEED CONTROL
QUICK CHANGE STOP ARM
CAM LOCK STOP ARM HEIGHT ADJUSTMENT
QUICK CHANGE STOP SYSTEM There are many ways to set the stops on the stop arms all depending on personal preference, material and finished product specifications. The illustrations below will reflect Norfield’s recommendations for setups for square stop, mitered stop and square stop on jambs with a lug dado.
10-24 x 3/4” & 10-24x 1-1/4” STOP BOLTS
STOP THICKNESS
SIDE JAMB W/ SQUARE STOP
21
SETTINGS & ADJUSTMENTS
10-24 x 3/4” & 10-24x 1-1/4” STOP BOLTS
DEPTH OF RABBET ON JAMB
HEAD JAMB W/ SQUARE STOP
USE STOP ARM 5842-105 WITH STOP BOLTS REMOVED. TOE OF MITER IS FLUSH WITH EDGE OF RABBET
SIDE JAMB W/ MITERED STOP
22
SETTINGS & ADJUSTMENTS
MITERED STOP BLOCK (5842-020)
STOP ARM HEIGHT ADJUSTMENT BOLT
DEPTH OF RABBET ON JAMB
JAMB SUPPORT DISK
10-24 x 3/4” STOP BOLT
HEAD JAMB W/ MITERED STOP When running head jambs with mitered stop, adjust the jamb support disk so that it clears the bottom of the jamb by about 1/32”. Adjust the height of the stop arm so that when the jamb is inserted the mitered stop block forces the jamb down against the support disk. This will hold the jamb in place and insure proper positioning of the stop material.
LUG DADO STOP ASSEMBLY (5801-701)
10-24 X 2-1/2” MACHINE SCREW
STOP THICKNESS
SIDE JAMB W/ LUG DADO
23
SETTINGS & ADJUSTMENTS
JAMB AND STOP CLAMPS: The jamb and stop clamps cylinders are plumbed in such a way that air is always supplied to the rear ports keeping the cylinders extended and the clamp shoes in position. When the machine is at rest (not driving fasteners) air is supplied to the cylinders through the low pressure regulator. This allows the material to be inserted into the machine and accurately referenced with a minimum of force required by the operator. When the cycle is started, the air supply switches to the high pressure regulator which provides maximum force to keep the material referenced for consistent reveal. If more or less pressure on the clamps is desired for material insertion, adjust the low pressure regulator accordingly. We recommend however, that the high pressure regulator remain set at 90 PSI.
JAMB CLAMP CYLINDER
STOP CLAMP CYLINDER
HIGH PRESSURE REGULATOR (SET AT 90 PSI)
LOW PRESSURE REGULATOR (SET AT 60 PSI)
JAMB AND STOP CLAMPS
POWERFEED WHEELS: The flow control valves on the infeed powerfeed wheels should initially be adjusted so that the wheels lift in 1 second and retract in 5 seconds. This is a starting point only, as lift speed is used to regulate the distance between the first and second staple / nail.
RETRACT SPEED CONTROL
LIFT SPEED CON-
POWERFEED WHEELS
24
TROUBLESHOOTING
TROUBLESHOOTING The operation on the 450 Flow Thru Stitcher is straightforward. A pair of inputs to the programmable controller (Start Button & Material Detect Photo-Eye) results in outputs at predetermined times which actuate solenoid valves. The solenoid valves in turn fire the staple / nail guns and power the air cylinders that reference the material and lift the powerfeed wheels. Should a problem occur, first check for correct electrical and air supplies (120 VAC and 120 PSI). If a problem with the staple/nail spacing occurs (i.e. the distance between the first and second staple is not the same as the distance between all the rest), check the adjustment of the flow control valves on the powerfeed cylinders (see “Powerfeed Wheels” on previous page). The length of time between the start of the cycle (first staple) and the powerfeed engaging the material and moving it determines the distance between the first and second staple. Remember, the speed at which the cylinder travels is controlled by restricting the exhausting air. To increase or decrease the extension speed, adjust the flow control on the rod end of the cylinder. If you experience electrical or pneumatic problems, check for loose wiring and/or air leaks first. Listed below are suggestions to aid in diagnosing various problems. The schematics at the end of this manual are also useful tools.
PROBLEM Cycle does not start.
POSSIBLE CAUSE
SOLUTION
No power to the machine. Service disconnect open or main breaker tripped.
Close disconnect or reset main breaker.
Emergency Stop pushed “IN”
Pull “OUT” Emergency Stop
Power fuse blown (lower fuse holder). Replace fuse (15 Amp.) No PLC inputs. LED 03 and/or LED Check contact block on cycle 09 should be ON when either / or start start switches. Check foot pedals also. button or foot pedal is pressed and held.
Powerfeed motor does not turn “ON”.
No PLC inputs. LED 04 and/or LED 10 should be “ON” when material is inserted in the machine
Check material sensing photo eyes. Replace if necessary.
Defective PLC. The power LED should be on when the Emergency Stop is pulled “OUT”.
Replace PLC - Contact Norfield’s Service Department.
Defective contact block on Emergency Replace contact block(s). Stop switch. Motor fuse blown (upper fuse holder). Replace fuse (10 Amp.) Defective motor
Powerfeed motor does not turn “OFF”.
Replace motor.
Defective contact block on Emergency Replace contact blocks(s). Stop switch.
25
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
Solenoid valves do not oper- Deficient air supply. ate.
Air cylinders do not operate.
Staple gun does not fire.
Last staple does not fire.
26
SOLUTION Check regulators and filter elements.
No PLC output.
Replace PLC - Contact Norfield’s Service Department.
Defective coil.
Replace coil.
Deficient air supply
Check regulators and filter elements.
Defective cylinder - no air should be exhausting from valves.
Replace cylinder.
Intermittent firing caused by malfunc- Clean / repair gun. tioning gun. Defective solenoid valve.
Repair / replace valve.
No PLC output. LED 00 and / or LED 04 should be on when gun is supposed to fire.
Replace PLC - Contact Norfield’s Service Department.
Toggle switch is “OFF”.
Turn switch “ON”.
No PLC inputs. LED 02 and LED 08 should be “ON” when toggle switch is “ON”
Replace switch. Replace PLC - Contact Norfield’s Service Department.
MAINTENANCE
MAINTENANCE
CAUTION: DISCONNECT ALL ELECTRICAL POWER AND AIR FROM THE MACHINE BEFORE PERFORMING MAINTENANCE OR SERVICE.
DAILY CLEANING (Every 8 Hours): 1.
Clean the machine by blowing it o with compressed air and wiping it down with a nonflammable, non-oil based solvent.
2.
Visually inspect the machine for any loose fittings or misalignment.
3.
Check a finished right and left hand jamb. Make sure the staples/nails are being set properly and that the reveal is correct.
WEEKLY CHECKS (Every 40 to 50 Hours): 1.
Thoroughly inspect the machine for loose nuts and bolts and check the entire machine for damage or wear.
2.
Check the oil level in the lubricators. Refill with 10wt turbine oil as needed.
3.
Check the filter elements in the FRL units. A visible coating of dirt or moisture is an indication that cleaning or replacement is necessary. The filter element can be removed and cleaned. Wash it in denatured alcohol then blow it out with compressed air.
4.
Check the pneumatic system for any leaking fittings or tubes.
27
WARRANTY
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 the 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 replaced 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, alterations 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 of warranties. Norfield expressly disclaims any warranty, expressed or implied, other than those which are expressly made in this limited warranty.
28
CONTACT & ORDER INFORMATION
CONTACT & ORDER INFORMATION Norfield Industries is the name that represents Quality, Reliability, Support, innovation and True Customer Service. We are dedicated to providing world class customer care. Norfield has been providing quality care in the pre-hanging door industry for over 40 years and has earned a reputation for setting the standard for innovation, reliability, full technical support, machine parts and a full line of industrial woodworking tools and accessories. Our team of Customer Care Representatives is available to support you. If you need to contact the Norfield Service department, please have the following information available: • Serial Number of the machine. • Model of the Machine. • Date of purchase or date that the machine was installed. • Voltage of the machine. • A description of the problem and in what part of the machine the problem is occurring. For warranty issues and service questions contact the Norfield Service Department at (800) 824-6242. To order replacement components and consumables, such as drill and router bits, saw blades and other accessories, contact a Norfield Tools and Supply Customer Care Representative at (800) 824-6242.
29
ASSEMBLY SCHEMATICS
PARTS AND ASSEMBLY SCHEMATICS TABLE OF CONTENTS General Assembly Frame & Frame Mounted Components Powerfeed Wheels & Pivot Assembly Powerfeed Drive Assembly Reference & Roller Assembly Material Stop Assembly Jamb Insert Reference Assembly Gun Mount Assembly Clamp Assembly Electrical Enclosure Pushbutton Enclosure Regulator - Lubricator Filter - Regulator - Lubricator (Lubricated Guns) Filter - Regulator - Lubricator (Non-Lubricated Guns) Powerfeed and Clamp Valve Assemblies
30
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
CLAMP VALVE/REGULATOR
CYCLE START FOOT PEDALS
PUSHBUTTON ENCLOSURE
JAMB INSERT REFERENCE ASSY
JAMB & STOP CLAMP ASSY
REFERENCE & ROLLER ASSY
GENERAL ASSEMBLY
ELECTRICAL ENCLOSURE
STAPLE GUN FRL
GUN FIRING VALVE
POWERFEED WHEELS
POWERFEED MOTOR
MATERIAL STOP ASSY
REGULATORLUBRICATOR
GUN MOUNT ASSY
ASSEMBLY SCHEMATICS
31
32
27
20
25
21
22
23
1
2
3
4
24
26
3
5
6
7
19
18
8
17
3
13
12
11
10
9
14 29
16
PART NUMBER 5817-002 5809-101 5860-019 5824-006 9510-400 13-505 5846-006 5846-004 5810-006 5810-007 5800-006 5806-101 5865-017 9520-225 5848-008 5848-009 5819-100 15-104 12-462 5806-100 5810-100 5827-005 5812-009 13-487 5811-100 5814-100 5847-100 10-480 10-450
DESCRIPTION Control Enclosure Support Infeed Ramp Weldment Guide Block Infeed Guide 5/16-18 x4" Threaded Shaft Reid STT-5T Knob Pivot Block Ramp Slide Angle Bracket Anti-Friction Pad Clevis Bracket Pivot Base (LH) Jamb Support 3/8-24 x 2-1/4" Redi-Thread Outfeed Support Outfeed Guide Motor Mount 1/4 HP 27 RPM Gearmotor Drive Sprocket Pivot Base (RH) Ramp Support Shim Lower Guide Block Magnetic Latch Main Frame Arbor Rack Drive Chain Guard ARO212-SS-120A Valve ARO CSN 1006 Strain Relief
FRAME & FRAME MOUNTED COMPONENTS
15
28
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 QTY 1 2 3 1 2 2 2 2 2 2 2 1 2 2 1 2 1 1 1 1 2 2 1 2 1 1 2 2 2
ASSEMBLY SCHEMATICS
PART NUMBER
9072-075 9072-150 5847-009 12-258 5842-101 5800-004 5800-005 9072-312 5847-011 12-402 12-038
DESCRIPTION
Square Key, .18 x .75 3/16 Square Key x 1-1/2" Modified Sprocket Flange Bearing Drive Support Bracket Tension Rod Pivot Bracket 3/16 Square Key x 3-1/8" Modified Sprocket Dodge #25 Torque Tamer Bushing Dodge #25 Torque Tamer
10
11
8
1
2
POWERFEED DRIVE ASSEMBLY
9
4 1 8 10 2 2 4 1 1 1 1
QTY.
SMALL DRIVE CHAINS: #35 X 19-1/8" + 1 OFFSET LINK (4 REQD) LARGE DRIVE CHAIN: #40 X 30-1/2 (1 REQD)
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 3
7
4
5
6
ASSEMBLY SCHEMATICS
33
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PART NUMBER
34
14
15
10-162 5800-002 5800-001 9072-250 5842-006 5841-003 12-258 5842-102 5800-003 5800-007 5842-007 13-1178 5842-103 ESNAP_750X_042 ISNAP-1_625X_062 12-024 5841-001 5842-100 10-562 10-484
DESCRIPTION
16
17
18
Bimba D-166-1 Clevis Pivot Block Spacer Square Key 3/16 x 3/16 x 2-1/2 Powerfeed Wheel Axle Drive Shaft Flange Bearing Powerfeed Swing Arm Spacer Spacer Powerfeed Wheel Axle 10" Powerfeed Wheel Powerfeed Swing Arm 3/4" External Snap Ring 1-5/8" Internal Snap Ring Nachi R12-2NSL Bearing Spacer Powerfeed Swing Arm 1/4T - 1/8P Flow Control Bimba BFT-092-D Cylinder
13
19
20
2 4 2 4 2 1 8 2 2 2 2 4 2 4 8 8 4 2 4 2
QTY.
1
2
12
3
11
POWERFEED WHEELS & PIVOT ASSEMBLY
4
5
10
6
9
8
7
ASSEMBLY SCHEMATICS
12
6
3
SEE NOTE #1
14
13
REFERENCE AND ROLLER ASSEMBLY
11
4
3
16
15
2
17
1
PART NUMBER
10
9
8
DESCRIPTION Tray Round Spacer Rear Jamb Guide Roller Shaft Reid AKA-3 Knob Stop Guide Reveal Spacer Reveal Plate Front Jamb Guide Base Plate 2nd Stop Guide Reveal Spacer Axle Spacer Roller Nachi 6000-2NSL Bearing Stop Guide Round Spacer
1 2 2 3 2 2 1 2 1 1 1 1 6 6 12 1 2
QTY.
ITEMS 7 & 12 ARE FOR A STANDARD 1-7/16" REVEAL. REMOVE THEM FOR 1-13/16" REVEAL.
THE FOLLOWING OPTIONAL REVEAL SPACERS ARE AVAILABLE: 1-1/2" 5865-018 & 5865-019 1-3/8" 5865-022 & 5865-023 1-5/32" 5865-020 & 5865-021
NOTE #1
5826-001 9011-038 5865-009 5860-001 13-422 5865-010 5865-013 5865-007 5865-008 5865-006 5865-011 5865-014 5860-016 5860-002 12-495 5869-002 9011-087
SEE NOTE #1
7
6
5
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
ASSEMBLY SCHEMATICS
35
36
6
5
4
3
2
1
14
13
12
16
15
11
7
8
9
10
PART NUMBER 5842-022 5842-021 22-031 5842-106 SC-1-0.500 5842-105 5842-019 5842-012 5842-013 10-970 10-1266 5842-015 12-080 5842-014 13-1016 5842-018
MATERIAL STOP ASSEMBLY
EXTENDED JAMB STOP (5842-023) (OPTIONAL)
MITERED STOP BLOCK (5842-020) (BOXED PARTS)
DESCRIPTION QTY. Stop Latch 2 Spacer 2 Century #666 Spring 2 Stop Block 2 Split Collar, 1PC,1/2" 2 Stop Arm 2 Pivot Shaft 2 Base Plate 1 Top Plate 1 SMC NCGUA20-0100 Cylinder 2 5/32T - 10-32NPT Flow Control Valve 4 Cylinder Mount 4 Aurora CW-4 Rod End 2 Side Plate 2 Cam Lock 2 Plunger 2
LUG DADO STOP (5801-701) (BOXED PARTS)
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ASSEMBLY SCHEMATICS
3
4
5
6
2
1
8
7
PART NUMBER 10-969 5842-009 5842-104 5842-008 9510-400 9011-234 13-505 5842-010 DESCRIPTION SMC NCQ2L25-10D Cylinder Adjustment Plate Stop Button Base Plate 5/16-18 x4" Threaded Shaft Round Spacer Reid STT-5T Knob Cover
JAMB INSERT REFERENCE ASSEMBLY
ITEM NO. 1 2 3 4 5 6 7 8 QTY. 2 2 2 1 4 4 4 1
ASSEMBLY SCHEMATICS
37
38
1
28
27
3
25
29
13
GUN MOUNT ASSEMBLY
26
2
4
5
6
24
8
7
23
22
12
11
9
21
10
20
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 PART NUMBER 5847-004 5837-001 13-228 5847-005 5847-006 10-562 10-322 5837-006 5837-007 12-083 5836-100 9520-262 5836-005 5836-003 5836-006 5820-006 5837-003 12-349 5818-100 5837-004 5866-101 5836-004 5820-010 5820-008 5818-101 5820-007 5866-100 5820-002 5836-001
19
15
14
13
18
17
16
DESCRIPTION Pivot Tab Adj. Base Plate Spring Plate 1/2" Crutch Tip Pivot Tab Adj. Base Plate Pivot Tab SMC FLOW CONTROL,1/4T X 1/8P Bimba 040.5-D Cylinder Cylinder Mount Crutch Tip Body Aurora CW-6 Rod End Pivot Block 3/8-24 x 2-5/8" REDI-THREAD Connecting Link Pivot Block Pivot Rod Adjustment Angle Tapped Axle Ball Bearing Bearing Bracket Axle Gun Mount Pivot Block Pivot Plate Secondary Plate Bearing Bracket Adjustment Angle Gun Mount Secondary Plate Pivot Block
QTY. 1 2 2 1 4 2 2 2 2 4 2 2 4 2 4 1 2 4 1 2 1 2 2 1 1 1 1 1 2
ASSEMBLY SCHEMATICS
10
9
8
7
6
5
4
3
2
1
11
12
15
14
13
16
17
21
17
18
16
19
20
PART NUMBER 5865-002 5849-004 5865-003 5865-001 5802-102 5860-014 12-494 5860-015 5865-004 5865-005 5803-101 10-164 10-135 5803-005 5803-004 12-110 12-336 5803-100 12-109 5802-101 12-082 QTY. 1 4 1 1 2 2 4 2 1 2 2 4 4 2 2 8 8 4 4 2 4
DESCRIPTION Stop Clamp Shoe Modified Shoulder Bolt Jamb Clamp Shoe Stop Clamp Shoe Stop Clamp Arm Roller Shaft Ball Bearing Spacer Jamb Clamp Shoe Roller Bracket Pivot Plate Bimba Bracket D-167 Bimba 092-DP Cylinder Dutch Clamp Dutch Clamp Thrust Washer Thrust Washer Jamb Clamp Arm Thrust Washer Stop Clamp Arm Aurora CW-5 Female Rod End
CLAMP ASSEMBLY
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
ASSEMBLY SCHEMATICS
39
40 5
6
ELECTRICAL ENCLOSURE
4
3
2
1
7
10
13
14
Fuse Holder Mounting Bracket Banner S18SN6FF100 Photo Eye
11-055 11-113 11-1570 13-1076 11-462 11-650 11-175 5825-005 11-667
6 7 8 9 10 11 12 13 14
8
9
11
Linemaster 522-B14 Switch Guard 15 Amp Fuse 10 Amp Fuse
11-318 25-006
4 5 GROUND BAR Bryant 5266-N Plug Grainger T-91-SWAN038s Foot
Buchanan 125 Terminal Block Programmable Controller
5860-018 11-413 11-319
Electrical Enclosure Toggle Switch Buchanan 130 End Cap
DESCRIPTION
1 2 3
12
ITEM PART NUMBER NO.
2 4 2
2 1 1
1 1 2
25 1
1 2 1
QTY
ASSEMBLY SCHEMATICS
5
6
4
3
2
1
11-053 11-049 11-048 11-047
3 4 5 6
Control Enclosure
N.C. Contact Block
N.O. Contact Block
Pushbutton
Emergency Stop Operator
PUSHBUTTON ENCLOSURE
6
5
4
5817-001
2
ITEM DESCRIPTION NO. PART NUMBER 1 5821-008 Control Panel
2
2
2
1
1
1
QTY
ASSEMBLY SCHEMATICS
41
42 3
4
REGULATOR - LUBRICATOR
1
ITEM NO. 1 2 3 4 PART NUMBER 10-546 10-710 10-526 10-545
(USED ON ALL MODELS REGARDLESS OF GUN TYPE)
2 DESCRIPTION Mounting Bracket Lubricator Regulator Adaptor
2 1 1 1
QTY
ASSEMBLY SCHEMATICS
SEE NOTE #1
3
2
4
5
8
FILTER - REGULATOR - LUBRICATOR (LUBRICATED GUNS)
1
PART NUMBER 10-546 10-551 10-523 10-547 10-526 10-711 5151-006 10-517 DESCRIPTION Mounting Bracket Shut-Off Valve Filter Manifold Regulator Lubricator Manifold Sleeve
2 1 1 1 1 1 1 2
QTY
6
7
NOTE #1: Replacement Filter Element = Wilkerson FRP-95-236 - (10-566)
ITEM NO. 1 2 3 4 5 6 7 8
ASSEMBLY SCHEMATICS
43
2
44
SEE NOTE #1
3
1
4
5
FILTER - REGULATOR - LUBRICATOR (NON-LUBRICATED GUNS)
SEE NOTE #2
8
PART NUMBER 10-546 10-551 10-523 10-543 10-547 10-526 5151-006 10-517
DESCRIPTION Mounting Bracket Shut-Off Valve Filter Coalescing Filter Manifold Regulator Manifold Sleeve
QTY 2 1 1 1 1 1 1 2
6
7
NOTES: 1. Replacement Filter Element = Wilkerson FRP-95-236 (10-566) 2. Replacement Filter Element = Wilkerson FRP-95-160 (10-557)
ITEM NO. 1 2 3 4 5 6 7 8
ASSEMBLY SCHEMATICS
45
4
3
2
4
1
PART NUMBER
RIGHT HAND
3
10-480 10-309 10-031 10-450 10-464
POWERFEED & CLAMP VALVE ASSEMBLIES
LEFT HAND
5
ITEM NO. 1 2 3 4 5 DESCRIPTION
5
ARO212-SS-120A Valve Mini Regulator Suttle Valve ARO CSN 1006 Strain Relief Pressure Gauge
2
2 4 2 2 2
QTY.