APC-61 Revision Control List

Transcription

1 APC-6 Revision Control List Manual No. Date Bulletin Code S/N applied History Page US Jan/7/00 (First Edition).Correcting the description of "- Hydraulic Pressure Does not Operate." -0.Correcting the Hydraulic Circuit to (For S/N 0000 to 899) and (For S/N 00 or above). 5-. US Jun//00.Adding precautions on P.C.board and ROM IV.Adding the relay in the control box 6-.Correcting producers No. for the rlay 7-8.Correcting wiring diagrams 7-6, 7-0, 7- -9,-0,-,- US Feb/7/008. Adding the 6II-related pages.,-,-5,- 6,-7,-8,- 6,-7,6-5,6-6,6-7,6-8,6-9,7-,7-5,7-6,7-7,7-8,7-9. Correcting the term "cut knife" to the "cutting knife". All Page. Correcting the term "back gauge" to the "backgauge". All Page

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3 FOREWORD Paper Cutter Model APC-6 Important Information This service manual is designed to help you to repair and maintain the APC-6 in order to keep it in good operating condition. Please read and understand the instructions in this service manual before performing any repair or maintenance. - Horizon International Inc. shall not be liable for incidental or consequential damages resulting from: improper or inadequate maintenance by the customer; unauthorized modification or misuse; or operation outside of the environmental specifications for the product. - Horizon International Inc. follows a policy of continuing improvement in design and performance of the product. Therefore, the product design and specifications are subject to change without prior notice and without our legal obligation. - All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without the prior written consent of Horizon International Inc. 080/APC6/0E/KY/NT/P6/I9/P7 US5000-0

4 Safety Precautions - Please read and understand all safety instructions which include the terms WARNING, and CAUTION. If these safety instructions are ignored, personal injury may result. - The repair, maintenance and safety instructions in this manual are valid only when the repair or maintenance work is performed according to the procedures described in this manual. - The term WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. - The term CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It may also be used to alert against unsafe practices. - Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in this manual and the warning labels on the machine are therefore not all-inclusive. - All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation, repair or maintenance could cause injury to personnel. Do not attempt to operate any switch, valve, or any electrical device when it has been locked or tagged out. - Some of the drawings in this manual show the machine uncovered for explanations of the details inside the machine.

5 I. Necessary Tools for Maintenance and Repair Use the following tools for maintenance and repair.. Screw Driver No.. Screw Driver 6 to 7 mm. Allen Wrenches.5,,.5,,, 5, and 6 mm. Open-ended Wrench 5.5 x 7, 8 x 0, x 7 mm 5. Box Wrench 5.5 mm 6. Snap-ring Expander II. Abbreviations in This Manual. The following abbreviations represent wire colors. Abbreviation Color Abbreviations Color BRN Brown PNK Pink RED Red LBL Light Blue ORN Orange YEG Yellow Green YEL Yellow YEO Yellow Orange GRN Green LYE Light Yellow BLU Blue GND Ground VIO Violet GRY Gray WHT White BLK Black. The following abbreviation represent electronic and electrical parts. Abbreviation Meaning CL Clutch BK Brake SW Switch PS Proximity Switch msw Micro-switch M Motor LED Light Emitting Diode VR Potentiometer RY Relay AS Assembly -5 Entering Service Screen means "Normal Cutting" Screen "Maintenance" Screen "Information" Screen "Numeric Keypad" Screen Fiv umeric ke. umbers our digits separ utton is pressed,the 0 = Total Counts Setting r e.) CAUTION iz "Service" Screen Moter Home Position Display Refer to -7 f..c.b. OK] b wp.b. wn.. alue will a page that is related to APC-6II. -9

6 Contents FOREWORD... Paper Cutter... Model APC-6... Important Information... I. Necessary Tools for Maintenance and Repair... II. Abbreviations in This Manual.... Machine Parts Descriptions - General View Operation Panel Descriptions (T6) Operation Panel Descriptions (M6) Cover Descriptions Entering Service Screen (6II) Calibration of Home position (6II) Checking Motor Home Position Distance (6II) Troubleshooting - blinks on the Display (Backgauge Does Not Operate) Part... - Part... - Part... - Part Cut Size is Not Equal Part Part Knife Does Not Lower (Clamp Does Not Lower Either) Part Part Part Knife Does Not Lift Part... - Part Clamp Lowers but Knife Does Not Lower Clamp Does Not Lower Though Foot Pedal Is Stepped On Backgauge Does Not Operate Part Part Backgauge Does Not come Forward (But goes backward) Backgauge Operates By Itself Nothing Is Shown on Displays Hydraulic Pressure Does Not Operate Knife Is Down before Operation Knife Lower Limit Position Varies Backgauge Does Not Move (6II) Error Code (6II)... -

7 .Adjustment - Fine Adjustment of Cut Size (Different is about 0. mm) Adjustment of Cut Size (Different is about between 0. and 0. mm) Rough Adjustment of Cut Size (Different is about 0.5 mm) Adjustment of Electromagnetic Brake Gap Adjustment of Electromagnetic Clutch Gap Adjustment of Knife Replacement Position Adjustment of Knife Lower Limit Position Adjustment of Cutting Line Width Release of Locked Knife Pressure Adjustment of Hydraulic Pump Right Angle Adjustment of Backgauge to the Table Horizontal Adjustment of Backgauge to the Table Parallel Adjustment of Backgauge to the Knife Backgauge Drive Section Mechanism (6II) Spindle Section Mechanism (6II) Repair - Replacing Knife Holder Replacing Clamp Replacing Backgauge Replacing Backgauge Block Replacing Knife Link A and B Replacing Clamp Link A and B Replacing Joint (For Clamp) Replacing Joint (For Knife) Replacing Rod End Replacing Rod Replacing Encoder Replacing Electromagnetic Brake Replacing Electromagnetic Clutch Replacing Belt (For High Speed) Replacing Belt (For Low Speed) Replacing Motor (For High Speed) Replacing VC Relay and Contactor Replacing Sensors (Detecting Knife Replacement Position, Knife Lower Limit Position) Replacing Power Supply Replacing Operation Panel Replacing Control Board Replacing Fuse and Resetting Thermal Relay Replacing Limit Switches Replacing Knife Holder Upper Limit Position Sensor - -5 Replacing Limit Switch for Clamp Upper Limit Position Replacing Cutting Line Bulb Replacing Electromagnetic Valve

8 5.Hydraulic Parts 5- Hydraulic Parts Description (For S/N 0000 or above) Hydraulic Circuit (For S/N 0000 to 899) (For S/N 00 or above) Hydraulic Parts Descriptions (For S/N or below) Hydraulic Circuit (For S/N No or below) Electrical Parts Description 6- Identification and Location of Motors and Encoder Identification and Location of Sensors and Switches Identification and Location of Components in the Control Box Location and Name of Pairs in Control Box(6II) Panel Internal Layout and Name (6II) Hydraulic Pressure and Motor Unit Layout and Name (6II) Backgauge Motor Section Layout and Name (6II) Parameter Settings of Amplifier for Servo Motor (6II) Control Board (QPW-5D), LED and Main Parts Control Board (QPW-5D) Connector Layout Foot Switch Control Board (QPW-55A) Foot Switch Control Board (QPW-55A) Control Box Schematic Diagram Wiring Diagram Terminal Terminal- Wiring Diagram (Inside of Control Box) LED and DSW of Control P.C.B. P08(QPM-95) (6II) LED and DSW of Panel P.C.B. P078(QPM-57) (6II) P08(QPM-95) Connector Connection (6II) New Circuit (Power System) (6II) Safety Circuit Performance (6II) System Wiring and Connections 7- Board Connections CPU Board (QPW-6) Display Board M6:QPW-75, T6:QPW

9 .Machine Parts Descriptions - Machine Parts Descriptions Operation Panel Descriptions (T6) Operation Panel Descriptions (M6) Cover Descriptions Entering Service Screen (6II) Calibration of Home Position (6II) Checking Motor Home Position Distance (6II)

10 HYDRULIC CUTTER P S??. - General View Clamp This clamp holds sheets not to move the sheets when they are cut. (500 to,700kg/cm ) Knife Angle Adjust Lever Fix Screw Knife angle adjust lever is fixed with this screw. Knife Angle Adjust Lever The knife angle adjusted with this lever. Cutting Knife Cutting Knife ON/OFF Switch and Lamp When this switch is turned up, only clamping will be performed with lamp lighting. APC-T6 P+ - S c E Cutting Depth Adjust Dial This dial is used to adjust the knife lower limit position only when Knife Operation Mode Select Switch is turned off. Power Switch The type of this switch is the breaker. Paper Clamp Pressure Indicator Backgauge Adjust Knob This knob is used to adjust backgauge. Paper Clamp Pressure Adjusting Knob Oil Tank It can contain 0 liter of oil. Foot Pedal This pedal is used to lower clamp. -

11 - General View Control Box Light Switch When turning up the lever, the table is lightened up, but it becomes difficult to see the cut line. Backgauge This backgauge is the back stop of sheets to be cut. Back Table Pressure Support Plate Side Guides These guides are register plates for preparing the sheets right angle against cutting knife. Oil Gauge -

12 HYDRULIC CUTTER P S??. - General View Key Switch APC-T6 P+ - S c E Photoelectric Guard When there is a foreign object on the optical line between photoelectric guards, the ray is blocked and safety function operates. Therefore, knife and clamp does not lower. Oil Feed Cover For Backgauge Cutting Button A Cutting Button B This button and cutter A button must be pressed simultaneously to start to cutting operation. Backgauge Cover Motor encoder Section The high speed motor, low speed motor, electromagnetic clutch, brake and encoder are housed. -

13 - Operation Panel Descriptions (T6) Push-out Memory Lamp Repeat/Setup Lamp Full Memory Lamp This lamp lights when input memory is full. Operation Error Lamp Power Lamp Key Switch Hydraulic Pressure Lamp Hydraulic Pressure ON/OFF Switch HYDRULIC CUTTER APC-T6 High Speed Backward Button This button is used to move backgauge backward at high speed. Low Speed Forward Button This button is used to move backgauge forward at low speed. High Speed Forward Button This button is used to move backgauge forward at high speed. Repeat/Setup Select Button In normal operation, this switch must be set to the repeat mode. (The above repeat lamp lights up.) The size memory button must be set to the setup mode.(the above setup Lamp lights up.) Repeat Current position Setup Put-out Memory Presetting Program P+ P- S+ S- Setup No More Memory? Program No. Delete Opar Error? Step.No. Memory Push-out c E Replacing knife Push-out Memory Button ON Memory Button (for the Current Position) Step Delete Button Step Backward Button Step Forward Button Memory Button (for the Keypad Input) Knife Operation Mode Select Switch This switch is used select knife operation mode, cutting mode or knife replace mode. In normal operation, this switch must be set to the cutting mode. -5

14 - Operation Panel Descriptions (T6) Step Number Display Presetting Size Display Current Position Display This display shows the backgauge current position. Program Number Display Numeric Keypad Repeat Setup Put-out Memory No More Memory? Opar Error? HYDRULIC CUTTER APC-T6 Current position Presetting Program P+ P- S+ S- Program No. Delete Step.No. Memory Push-out c E Replacing knife ON Setup Program Forward Button Program Backward Button Program Delete Button Decimal Point/Clear Key The decimal point is input in the first press and the number is deleted for the delete key in the second press. Enter Key When this key pressed after inputting the number, the backgauge moves to the set position. -6

15 - Operation Panel Descriptions (M6) Step Number Display Program Number Display Current Position Display This display shows the backgauge current position. Hydraulic Pressure Lamp Power Lamp HYDRULIC CUTTER Presetting Size Display APC-M6 Current Position Display Memory Presetting Program No. Step No. Step Forward Step Forward Button Replacing Knife Be sure to set "knife Angle Adjustmant" knob and "Knife Operation Mode" select switch to each "Replacing Knife"Position Size Memory Button Push-out Memory Button Key Switch Hydraulic Pressure ON Button Hydraulic Pressure OFF Button High Speed Backward Button This button is used to move backgauge backward at high speed. Low Speed Forward Button This button is used to move backgauge forward at low speed. High Speed Forward Button This button is used to move backgauge forward at high speed. Power Hydraulic Backgauge Travel Step 5 6 Repeat / Setup Memory Delete Size Memory Cutting Operation & Knife Vertical Adjustment Be sure to set "knife Operation Mode" select switch to "cutting" Push-out position Memory knife Operation Mode Program Forward Program Extension Replacing Knife Cutting Knife Operation Mode Select Switch This switch is used to replace knife. In normal operation, this switch must be set to the cutting mode. Program Extension Button Program Forward Button Memory Delete Button Repeat/Setup Select Button In normal operation, this switch must be set to the repeat mode. The above repeat/setup Lamp lights up. The size memory button must be set to the setup mode. (The above setup Lamp lights up.) -7

16 - Cover Descriptions Backgauge Cover M05-0 Upper Cover Rear Cover L Front Cover Lower Cover Plate R Table R Rear Cover R Small Cover Side Gauge R Front Cover L Control Box Side Gauge L Back Cover B Plate L Table L Small Cover Back Cover A Back Cover U Back Cover L -8

17 -5 Entering Service Screen "Normal Cutting" Screen "Numeric Keypad" Screen 6 "Service" Screen 6 ent "Maintenance" Screen 6 Press the ent buttons. Total Count Input Up to five digits can be entered using the "numeric keypad" screen at once. Input the numbers the first three digits and the last four digits separately. When the button is pressed, the numeric keypad screen appears. Motor Home Position Display Refer to -7 for details. "Information" Screen Special Functions ( are not used.) = Total Count Setting = Cutting Program Clear = Resetting Home Position and Push-out Length to Default = Total Count and Count after Replacing Knife The total counts is memorized on the control P.C.B. When replacing the control P.C.B.,. Write down the total counts before replacing the P.C.B.. Replace a new P.C.B.. After replacement, press the 0 button and the [OK] button to clear the total counts of a new P.C.B.. Press the 0 button and input the total count number you wrote down. CAUTION Press the 0 button and the [OK] button. Saved cutting programs will be deleted completely. Deleted cutting programs cannot be restored. Press the 0 button and the [OK] button. Home positioning value will be set to 60.0, and the push-out length will be set to Press the 0 button and the [OK] button. Memorized total counts and count after replacing knife will be set to zero. -9

18 -6 Calibration of Home Position. Set the cutting length to 00.0mm. - This is the temporary value for comparing the set value with the actual cut length.. Cut some sheets. - Do not align the sheets on the side guide. Align the sheets only on the backgauge properly, and cut.. Measure the dimension of cut sheets. - Measure the dimension of the sheets by one decimal place. 00.6mm is given for an example here. 6. Check. - Follow the steps through and check that the set value matches the actual cut length. 7. Rewrite the home position sheet. - The home position sheet is attached to the bottom of the control panel box shown in Fig.. Rewrite the new home position on it.. Obtain the correction value. - Correction value is a half of the difference between the set value and the actual cut length. - The actual cut length is 00.6mm. Therefore, the correction value is 0.mm. Fig. "Backgauge Calibration" Screen _6_B 5. Enter a new home position. (Fig.) - Show the Backgauge Calibration screen. (Fig., Fig) - Add or subtract the correction value which was calculated in step to or from the current home position value, and enter the new home position value. (When the actual cut length is larger than the set value, substract the correction value.) - In the case of the example, enter the value which is subtracted by 0. and press the button. The backgauge will move to the new home position. Fig. "Maintenance" Screen _6_A The home position sheet is attached to the bottom of the control panel box _6_C Fig. Location of the Home Position Sheet -0

19 -7 Checking Motor Home Position Distance Explanation of "Home Positioning". At first, the backgauge moves backward and B home position sensor (Fig.) detects the sensor plate and turns on.. When B turns on, the servo motor M0 rotates in the reverse direction and moves the backgauge forward, and B turns off.. The motor stops at the position where Z-phase from the encoder is detected for the first time in one rotation of M0. This position is the home position. - The encoder is housed in M0. Checking the Motor Home Position Distance - The Z-phase cannot be detected correctly around the area that the B home position sensor turned off from on, and the boundary line of the first and second rotation of M0. If the Z-phase appears at these areas, the encoder may misread it, and detects the Z- phase which appears next. This will set the home position to the wrong position. Therefore, checking the home position distance is necessary to make sure the encoder reads Z-phase correctly in the stable area. Fig. "Service" Screen _7_A Explanation of "Motor Home Position Distance" - The motor home position distance is the distance between the position which the B home position sensor turns off from on and the position where the Z-phase from the encoder is detected for the first time in one rotation of M0. (steps and above). - One rotation of M0 servo motor is set to 50 in APC-6II. The position of the home position sensor B is set so that Z-phase will be detected at the middle of the motor rotation. Therefore, the motor home position distance should be around 5. (Fig.) M0 Servo Motor Sensor Plate Home Position Sensor Fig. Home Position Sensor B B 0007 _7_B -

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21 . Troubleshooting - blinks on the Display (Backgauge Does Not Operate) Cut Size is Not Equal Knife Does Not Lower (Clamp Does Not Lower Either) Knife Does Not Lift Clamp Lowers but Knife Does Not Lower Clamp Does Not Lower Though Foot Pedal Is Stepped On Backgauge Does Not Operate Backgauge Does Not come Forward (But goes backward) Backgauge Operates By Itself Nothing Is Shown on Displays Hydraulic Pressure Does Not Operate Knife Is Down before Operation Knife Lower Limit Position Varies Backgauge Does Not Move (6II) Error Code (6II)...- -

22 - blinks on the Display (Backgauge Does Not Operate) Part Why does blink on the display? Backgauge is traveled by the screw shaft which is driven by motor. Encoder is installed directly at the back end of the screw shaft, and the operation distance of backgauge is controlled by counting the number of pulse from the encoder. In case that pulse signal does not come from encoder while the backgauge is moving, blinks on the display inform to the trouble. Backgauge is at the front limit position. When backgauge is at the front limit position (in normal case about 5mm, when support plate is fixed about 75mm), limit switch is on. When turning the power switch on this condition, blinks on the display. After moving the gauge a little backwards with adjust knob, turn the power switch on again. Adjust knob remains being pressed Adjust Knob Snap Ring Spring Micro Switch Bearing Unit In normal case, the adjust knob is pressed by compression spring to the operation side. Even if you try to move the backgauge forwards or backwards when the adjust knob remains being pressed for some reasons, motor does not drive and blinks on the display because the machine is in manual mode. Shaft of knob is difficult to move. When the knob does not move smoothly forwards and backwards, check bearing unit. Lubricate when movement is dull. Snap ring unfastens. When snap ring (STW-0) unfastens, fix it again. - Compression spring is broken. When compression spring is broken, replace it with a new one. High Speed Motor Fuse Low Speed Motor Fuse A A 5 A 5 A 5 A 5 A Fuse is blown. When motor protection fuse is blown, screw shaft does not operate and no pulse rises from encoder. Replace fuse according to Ò-Ó and observe it.

23 - blinks on the Display (Backgauge Does Not Operate) Part Phase of power is lacking. Even if one of the three-phases AC power results in open phase, motor does not operate and blinks on the display. There is problem in control board. Backgauge belt is cut. Control Box Check input voltage which comes to every section of this terminal board between R-S, S- T, and T-R. When there is no voltage even at one point, original power is in open phase. 6 5 T S R LED SSR Cement Resistance Cement resistance is damaged When switching the motion of the backgauge (forwards or backwards), short circuit exists momentarily and this cement resistance can be damaged. In this case, replace P.C.B. LEDs from No. to No.6 do not turn on. When LEDs from No. to NO.6 showing operation of knife, clamp, and backgauge turn on normally, input signals are OK. If there is no problem in output motor, SSR may has a problem. Replace P.C.B. - Control Box Varistor 6 5 Low Speed Belt High Speed Belt Motor Blacket High Speed Motor When belt is cut or overturned, power is not transmitted and screw shaft does not drive. Therefore, no pulse rises from encoder. Replace belt with a new one. As for high speed belt for S/N 000 or above, a new wider belt is used which is hard to overturn. To attach this wider belt to a previous machine, gauge base and motor base also must be replaced. (In case of order, please notice it.)

24 - blinks on the Display (Backgauge Does Not Operate) Part Coupling of encoder unit is broken Screw Shaft Coupling Encoder Adjust knob is heavy Gauge Rail There is problem in encoder. Encoder is very delicate. When its shaft bends because of external shock, it does not operate correctly, even if it is connected with coupling. Stay Coupling Encoder Bracket Encoder Set Screws When coupling is broken or set screws are loose, rotation of screw shaft is not transmitted to encoder and no pulse rises. When coupling is broken, replace it with a new one. When set screw is loose, fasten it again. Adjust Knob Adjust Nut Screw Shaft Fix Nut Adjust nut and fix nut prevent screw shaft returning (backlash) of the backgauge. When there is problem in screw shaft, nuts or guide, screw shaft is hard to move and normal pulse does not rise. Therefore, blinks on the display. Oil on rail and screw shaft is running out. When oil is running out, lubricate operating the backgauge for-and backwards to circulate oil. There are some foreign objects on rail and screw shaft. When there are some foreign objects such as paper dust, wipe them off and lubricate enough. Screw Shaft Axis difference or bent of shaft should be within 0.mm. When there is an axis difference as shown in the drawing, replace not only the coupling but also the bracket and the stay. There is contact failure or breaking of cable from encoder. Check the voltage between terminal 6 and 8 on the terminal board (refer to page 7-) while rotating the adjust knob slowly. If the voltage changes while rotating the knob signal is output from encoder normally. -

25 - blinks on the Display (Backgauge Does Not Operate) Part Motor has burned out Backgauge is moved by motors. Above all, high speed motor repeats driving in the normal and reverse direction according to using condition. For each motor circuit, there is 5A fuse. However, after using for many years, motor insulation weaken gradually and motor coil burns out without blowing of fuse. Brake surface smuts. Brake 0.5 to 0.mm Encoder Control Box 6 5 TAN- High Speed To check motor coil, For high speed motor: Check continuity among pins, 5, 6 on TAN- on control board. For low speed motor: Check continuity among terminals,, 6 on electromagnetic contactor VC- in control box. Motor Low Speed Motor A06 VC- A 95 Armature Coupling There is a gap between brake and armature for 0.5 or 0.0mm. when brake surface smuts with metal powder because of surface wear, semi-brake condition occurs and drive system of backgauge becomes heavier. In this case, clutch operation becomes dull and correct pulse does not rise. Therefore, blinks on the display. Remove the metal powder with compression air or wipe off paper. -5

26 - Cut Size is Not Equal Part Backgauge position is determined only by high speed for- and backward buttons. When backgauge is operated only using the high speed forward or backward button, the backgauge can not stop in the correct position because of overrun. Determine precious position using low speed forward button or forward operation with adjust knob. Set screw of coupling is loose. Brake Encoder Backgauge driving belt is loose. Set Screws High Speed Belt Motor Bracket Low Speed Belt High Speed Belt High Speed Motor Motor Pulley to mm Low Speed Belt to mm Coupling Encoder When set screw is loose, rotation of screw shaft is not transmitted to the encoder accurately, As a result, the size indicated on the display becomes different from the actual cutting size. Adjust it referring to ÒAdjustment of Cut SizeÓ, from - to -. The high speed belt is bent by to mm, low speed belt to mm, when the part pointed with an arrow is pressed by kg force. Tension of high speed belt can be adjusted by position of motor bracket, low speed motor by idle pulley. Adjust able range of idle pulley becomes larger when it is attached upside down. -6

27 - Cut Size Is Not Equal Part VDC is not output from power supply. Gap of clutch or break is not correct. Operation Side If output voltage of power supply PW- is too low, the backgauge is delayed moving or stop and the cumulative defference gets larger. Check whether there is VDC output between and. Check whether there is 00VAC input between and 5. When there is not VDC output in spite of 00VAC input, replace power supply. 5 PW- Power Supply PW- Brake 0.5 to 0.0 Clutch Gap of brake should be 0.5 to 0.0 mm. Gap of clutch should be 0. to 0. mm. 0. to 0. When gap of brake or clutch is not in these ranges, the time lag results in the motion of the screw shaft. Therefore, defference between the indicated size on the display and the actual cut size results. Adjust it to correct gap. Or when there is foreign object such as metal powder on friction surface, remove it with compression air or wipe off with paper. -7

28 - Knife Does Not Lower (Clamp Does Not Lower Either) Part Cutting button A and B are not pressed simultaneously. For safety, when the timing to press cut buttons A and B differs more than 0.5 second, the machine judges the abnormal operation and hydraulic system does not operate. Press them simultaneously (within 0.5 second). Knife is not at the upper limit position. The cutting operation does not start when either knife or clamp is not at the upper limit position. Check the sensor for upper limit whether knife is at the upper limit position is observed by sensor. Front Cover Clamp is not at the upper limit position. Control Box There is a problem with cutting button A or B. When each of cuttig button is pressed separately and slowly, it sounds click. When there is no sound, there is mechanical problem or of switch itself. Replace the cutting button switch. The cable from cutting button switch is connected with the machine under the front table. Disconnect this connector and check the continuity with a tester. If there is the continuity with cutting button pressed, it is OK. If there is no continuity, replace cutting button switch. When LED L and L on control board (See Ò7- Control BoardÓ) lights for a moment and go out again at the moment of pressing cutting button, knife or clamp does not reach to the upper limit position. See the next description. Remove front cover and check whether sensor lamp is on. Sensor Sensitive Area When the lamp is on, knife is at the upper limit position. When the lamp is not on though knife is at the upper limit position, put a piece of metal to sensitive of the sensor. If the lamp turns on, sensor operates properly. Lower the sensor bracket. -8 Sensor Fixing Blacket Lamp The limit switch detecting the clamp upper limit position should be on. Dock Dock Lamp Upper Limit Position Detecting Switch When this actuator is turned to the right, there must be no detection sound. Lamp Upper Limit Position Detecting Switch Or check continuity between 8 and 9 of CON on control board with tester.

29 Opar Error Replacing Knife Be sure to set "knife Angle Adjustmant" knob and "Knife Operation Mode" select switch to each "Replacing Knife"Position Cutting Operation & Knife Vertical Adjustment Be sure to set "knife Operation Mode" select switch to "cutting" position Replacing Knife - Knife Does Not Lower (Clamp Does Not Lower Either) Part There is an obstruction between beam guards. Beam Guards Ray Obstruction When there is an obstruction on the optical line between beam guards, the beam is blocked and safety function operates. Therefore, knife does not lower. There is trouble with foot switch control board. If board is replaced and problem disappeared, some of relays on the board has the contact failure. Some of switches on operation panel remains on. (APC-M6) HYDRULIC CUTTER Power APC-M6 Hydraulic (APC-T6) HYDRULIC CUTTER APC-T6 Repeat Current position Setup Current Position Display Backgauge Travel For APC-M6: Any of the step forward button, the size memory button, and the push-out memory button remains pressed. Put-out Memory Presetting For APC-T6: After button is pressed, there is no sound and it does not return. When any of the switches are out of order or remain pressed, the machine judges that it is in the setting mode. Therefore, hydraulic system does not operate. -9 Program P+ P- S+ S- Setup Memory Presetting Program No. Step No. Step 5 6 Repeat / Setup No More Memory? Program No. Delete Memory Delete? Step.No. Memory Push-out Step Forward Size Memory c E Push-out Memory knife Operation Mode Program Forward Program Extension Replacing knife ON Cutting There is problem in control board. Control Box Varistor SSR LED Cement Resistance SSR (solid stay relay) or cement resistance is damaged. If its white exterior is broken or cracked because of heat, cement resistance get damaged. And if there is continuity between the two parts of the bottom in the following drawing, SSR is out of order. However, no continuity does not always mean normal. If there is continuity, SSR is out of order. If this part is damaged, hydraulic pressure is not applied. Replace the board. If knife does not lower though hydraulic pressure applied, check the hydraulic valve. 6 5

30 - Knife Does Not Lower (Clamp Does Not Lower Either) Part Hydraulic valve does not operate correctly. Hydraulic Section [Valve Section] [Electromagnetic Valve] Remove the apron cover under the table and check whether LED of electromagnetic valve turns on, when cutting button is pressed. Spark Killer LED [Top of Electromagnetic Valve] If LED turns on, the signal comes correctly. The internal damage of electromagnetic valve can be considered. Replace electromagnetic valve. Grease on clamp rails is not enough to move the clamp. Clamp lifts and lowers guided by right and left rails. However, when there is not enough grease between clamp and rail, clamp is difficult to move because of metal friction and does not return to the upper limit position. When the upper limit position of clamp is not detected, cutting operation does not start. Rail Rail Clamp [Back view of the machine] When there is enough grease on part of right and left rail, there is no problem. When there is little grease, lubricate with a grease gun. (See Ò6- LubricationÓ in operation manual.) -0 There is problem in clamp link. Link A Sprocket B Sprocket A Hook shaft Chain Chain Clamp Spring Check the followings. Chain is damaged. Sprocket A or B is detached from shaft. Spring is detached or loose. (For old model link A) needle bearing is detached. When an old model of the machine has link A. When there is problem with any of these parts, clamp can not be lifted and return to the upper limit position. When clamp is not the upper limit position, the machine can not start cutting operation.

31 - Knife Does Not Lift Part When cut buttons are pressed, first clamp lowers. Second, knife lowers to cut. After that, knife stops and does not lift again. (Clamp does not lift either.) Or when you release your hands from cut buttons, knife lifts again. However, Step does not proceed automatically. The depth of knife is too short. [When knife resharpened for many times is used] Resharpened and shortened knife should be lowered to cutting stick by loosening screws of knife holder according to 6- Knife Replacement of operation manual. However, in this case, the tip of knife does not reach to the cutting stick, though screws are lowered to the lowest position. In this condition, if cutting operation starts with all 7 screws tightened, sensor can not detect the tip of knife. Therefore, knife tries to continue lowering. Replace knife to new one and operate again. Lift the knife with the cutting depth adjust dial in advance. Otherwise new knife can cut into the cutting stick. Knife does not touch cutting stick when replacing knife. When replacing knife, loosen screws of the knife fastened at the lower limit position in Knife Replace Mode, and lower knife until the end of knife touch cutting stick, and fix knife again. Otherwise, knife tries to continue lowering during normal cutting operation, because knife is not detected by the lower limit sensor. Screw knife Cutting Stick No Gap After replacing knife, the position of knife lower limit position sensor is still lower. Ajusting Knife's Lower Dead Point Down UP When using knife resharpened for many times, the position of lower limit position sensor must be adjusted depending on shortened length of knife. However, if the position of lower limit position sensor does not change after replacing knife with a new one and knife lowered, knife cuts into cutting stick. Therefore, knife is not detected by sensor and hydraulic system continue operating so that knife continues lowering. After releasing your hands from cut buttons and knife lifts, adjust the position of lower limit position sensor upward. 7 Cutting Depth Adjust Dial -

32 - Knife Does Not Lift Part Knife lower limit position sensor does not operate correctly. LED LED Knife Exchange Position Sensor Lower Limit Position Sensor When knife lower limit position sensor is out of order with its switch off, it does not detect knife at the detection point and no signal rises. Therefore, the machine determines knife does not reach the lower limit point and operates to continue lowering knife. WARNING Turn off the switch of hydraulic pressure before the following operation. Otherwise heavy accident will result. When knife is at the upper limit position, measure the voltage between and 5 of CON on the control board (See 7-5 Control Board, Connector Layout) is 5VDC. Next, in this situation, approach a ferrous piece within mm. If the voltage changes into 0V, the sensor has no problem. (LED of the sensor turns on.) Sensor V Output 0V RED WHT Shield If the voltage remains 5VDC though ferrous piece is approached, the sensor is out of order with its switch off. -

33 -5 Clamp Lowers but Knife Does Not Lower Clamp operates only and knife never operates, though cut buttons are pressed. Cutting knife ON/OFF switch is on. View A Knife Lower Limit Position Sensor Cutting Knife ON/OFF Switch When cutting knife ON/OFF switch is on, only clamp operates and knife does not operate. In normal cutting operation, turn off this switch. When pressed cut buttons, clamp lowers at first and knife begins to lower. But knife lifts before it is reached to the lower limit and clamp also lifts. Knife lower limit position sensor does not operate correctly. LED LED Knife Exchange Position Sensor [View A] Lower Limit Position Sensor If knife lower limit position sensor shortcircuits to ON side (close side), it determines that knife has reached lower limit position though it does not. Therefore, when knife begins to lower it soon returns to the upper limit position. WARNING Turn off the switch of hydraulic pressure before the following operation. Otherwise heavy accident can result. Check the voltage between and 5 of CON on the control board (See 7-5 Control Board, Connector Layout ). If it is 5VDC, sensor has no problem. However, if it is 0VDC, sensor short-circuits to ON (close) side. Sensor V Output 0V RED WHT Shield

34 -6 Clamp Does Not Lower Though Foot Pedal Is Stepped On. Joint or rod has problem. Stepping Position Detecting Micro switches are out of order (For T-58.) Rod End For machines of S/N or below, the drawing of rod is as follows. Rod RL Foot Pedal Micro Switch Cam Rod End Upper or lower rod end is loose and detached from rod. Or rod is broken. In either case, because the stepping force on foot pedal is not transmitted to clamp, that is why clamp does not lower. If rod is broken, replace it and adjust to the right position according to Ò-0 Replacing RodÓ. To replace it with the present one, not only upper and lower rod ends and rod but also hook on parts book Fig.-0 (M00-00) need to be replaced together. Check micro switches detecting the position of foot pedal. If they do not turn on or off though foot pedal is stepped on, check whether cams are loose. If the switches do not turn on or off though cams are not loose, micro switches are out of order. -

35 -7 Backgauge Does Not Operate Part Power is distributed to each motor. Motor coil is burnt out. There is problem with control board, Control Box Remove the motor terminals from each terminal board and check continuity among cables. 5 TAN- High Speed Check whether 00V voltage is output among these motor terminals. When there is no voltage, check whether power switch (breaker) is on or the following fuses are blown. Motor Low Speed Motor A06 VC- A 95 M 6 C When there is no continuity in any of A, B, and C, coil is burnt out inside the motor. Replace motor. Backgauge driving belt is cut. A B Control Box 6 SSR Varistor 5 Cement Resistance When the cement resistance (rectangle shape in white) is damaged, replace the whole board. High Speed Motor Fuse Low Speed Motor Fuse A A 5 A 5 A 5 A 5 A If belt is cut, replace it. High Speed Belt Low Speed Belt When LED 5 (backgauge forward) and LED 6 (backgauge backward) turn on, control signal from the board rises correctly. The damage of SSR can be considered. Replace it with the board. -5

36 Opar Error Replacing Knife Be sure to set "knife Angle Adjustmant" knob and "Knife Operation Mode" select switch to each "Replacing Knife"Position Cutting Operation & Knife Vertical Adjustment Be sure to set "knife Operation Mode" select switch to "cutting" position Replacing Knife -7 Backgauge Does Not Operate Part Adjust knob remains pressed. Adjust Knob Snap Ring Spring Micro Switch Bearing Unit Backgauge adjust knob is normally pushed to the operation side by spring. However, when knob remains pressed for some reason, micro switch turns on and the machine changes into manual mode. Therefore, backgauge does not operate. When the adjust knob remains pressed and does not return, check whether there is problem with snap ring, spring, and bearing. Any of switches on operation panel remains on. (APC-M6) HYDRULIC CUTTER Power APC-M6 (APC-T6) HYDRULIC CUTTER Hydraulic APC-T6 Repeat Current position Setup Current Position Display Backgauge Travel Memory Presetting Program No. Step No. Step 5 6 Repeat / Setup Memory Delete Step Forward Push-out Memory knife Operation Mode Program Forward Program Extension For APC-M6: Any of step forward button, size memory button, and push-out memory button remains pressed. For APC-T6: After button is pressed, it can be felt that the button returns back with a sound. Put-out Memory Presetting Program P+ P- S+ S- Setup No More Memory? Program No. Delete? Step.No. Memory Push-out Size Memory c E Replacing knife ON Cutting When any of the switches is out of order or remains pressed, the machine determines setting mode is operated. Therefore, backgauge does not operate. When the switch cap locks, return it to normal condition. When the switch itself is out of order, replace the board itself. (When replacement of switch itself only is possible, replace separately.) -6

37 -8 Backgauge Does Not come Forward (But goes backward) Limit switch remains ÒONÓ. SW Limit switch SW Limit switch (When pressure support plate is used.) Limit switch or shows normally ÒClosed (=NC)Ó. When backgauge moves forwards and activates limit switch, it shows ÒOpenÓ and stops backgaugeõs forward motion. If the actuator of limit switch is on or connector is disconnected, the control board determines the detection circuit is ÒOpenÓ and backgauge can not operate forwards. (Backgauge can go backwards.) Check of limit switch: See Ò7-5 Control Board, Connector LayoutÓ. CON WHT Control Box BLK 5 empty GRN 6 When there is continuity between 6 and 5 of CON, there is no problem with SW. When there is continuity between 6 and, there is no problem with SW. There is problem with high speed motor. Power is supplied to the high speed motor. Coil of high speed motor is burnt out. High speed belt is cut. There is problem with control board. As for these symptoms, follow the description in Ò-7 Backgauge Does Not Operate.Ó -7

38 -9 Backgauge Operates By Itself Check knife lower limit position sensor. View A LED WARNING Turn off the switch of hydraulic system before the following operation. Otherwise heavy accident will result. The voltage of power supply (PW-05) declines. CON7 Knife Lower Limit Position Sensor [View A] When ÒRepeatÓ mode is selected and lower limit position sensor is out of order with ON side (close side), the sensor determines wrongly that knife reached lower limit position soon after knife has begun to lower. Therefore, knife returns to upper limit position and backgauge move to the position for the next step. V 7 Control Box RED 6 Output Sensor WHT 5 5 Shield 0V When the voltage between and 5 of CON on the control board (See Ò7-5 Control Board, Connector LayoutÓ) is 5VDC with the knife at upper limit position, there is no problem with the sensor. When the voltage is 0VDC, the sensor short-circuits to ON side. Replace the sensor. PW-05 Power Supply (PW-05) When the voltage between and becomes lower than 5V, the operation of CPU board becomes unstable and operate wrongly. When under 5V, adjust the volume on this power supply board to supply the voltage between 5.5 and 5.5V to the CPU board. The voltage can be measured also on CON7 of the control board. (See Ò7-5 Control Board, connector LayoutÓ.) -8 When cable is pinched between power supply and control board, cover of the cable tears and the voltage can decline. In this case, put a piece of paper for insulation between them.

39 -0 Nothing Is Shown on Displays Fuse for electronic circuit is blown. Control Box Distributor does not operate. Check whether the breaker in the distributor is on. Check whether the fuse in the distributor is blown. There is problem with power switch. A A 5 A 5 A 5 A 5 A Power Switch Fuses for Electronic Circuit When fuse for electronic circuit is blown, P.C.B. does not operate and operation panel records nothing. Replace the fuse with a spare one in the control box. Check the continuity of power switch. -9

40 - Hydraulic Pressure Does Not Operate Thermal relay trips. Control Box Thermal Relay Contactor can not cut electricity because of heat. Thermal Relay Any of Phases is Open. The voltage 00V is not supplied among contactor output terminals,, and Reset Button Trip Bar 6 5 If there is excessive pressure on hydraulic system, thermal relay operates and contactor opens to shut the power off to protect the hydraulic motor. When thermal relay operates, trip bar is pushed in. When green reset button is pressed, thermal relay will be reset. 5 Contactor When hydraulic pressure is not on, There is electrification between and. There is electrification between and. There is electrification between 6 and 5. If there is electrification in any of these parts, contactor can not cut electricity because of heat. Replace thermal relay and contactor. If hydraulic pressure switch is turned on in this condition, the breaker of control box will operate or the fuse will blow. When there is no voltage at any of the three points, or when the voltage is declining to about 00V (Open phase), the thermal relay operates and hydraulic system does not operate. Check the circuit between the plug of this machine and the contactor. Reset Button -0

41 - Knife Is Down before Operation After finishing operation of the day before and turning off hydraulic pressure, the oil in hydraulic circuit return to the tank because of slight leak of oil from valves. Therefore knife lowers depending on the amount of leak through the night. As a result, when turning on the power on the next day and pressing hydraulic pressure switch, knife lifts a little to return to the upper limit position. If knife is not lower than clamp before turning on hydraulic pressure switch, there is no problem for safety and operation. When knife is lower than clamp, a large oil leak is occurring in hydraulic system. Remove the cover of the machine and check hydraulic system by the following procedure. WARNING Turn power switch off before checking hydraulic system. Oil is leaking at hydraulic hose joint. Touch the joint between hydraulic hose and each hydraulic parts. If oil clings to your finger, the connection of joint is not tight. Fix the parts side by turning the pipe side. Oil is leaking from hydraulic cylinder. When oil is leaking from this part pointed by an arrow, the problem with the cylinder packing can be considered. Replace cylinder or disassemble the cylinder and replace rod packing. When replacing rod packing, replace also dust wiper.if knife still lowers, there is problem with interior packing inside. Replace the whole cylinder. C spring to return the knife is cut. C spring I Bolt Hydraulic Cylinder When C spring is cut or loose, the force to return the knife to upper limit position weakens and knife lowers even by a slight oil leak. When spring is cut, replace it. -

42 - Knife Lower Limit Position Varies [Cause : Oil temperature variation] When this machine is operated for a long time, oil temperature rises and viscosity weakens. Therefore, the speed of hydraulic cylinder becomes slightly faster. When knife lowering speed becomes faster, because lower limit position becomes lower, lower limit position needs to be rised with the cutting depth adjust dial. When operation begins after long break, because oil temperature returns, uncutting occurs. The oil suited to ISO VG should be used. [Cause : The timing of lower limit position detection] The signal is sent with about 0msec cycle in this machine. Therefore, the time difference at 0m sec maximum between lower limit position detection and CPU exists. The variation are caused by the knife moving distance for this time. But this variation is in allowable range. [Solution] Because knife lower limit position changes depending on the oil temperature variation, adjust with cutting depth adjust dial for each time. For S/N 000 or above, because hydraulic unit is renewed and oil cooler is equipped as standerd, the temperature variation does not occur. -

43 - Backgauge Does Not Move - Check that the drive mechanism of the machine is not damaged. - Check that grease is applied. - Check that the electrical wiring is correct. Block X WHT BLK 00V 0V 06 T0 WHT L' BLK N' V A 0V Q 5A 58 L N RED L RED L BLK L Q A Q A Q 5A 5 L' L' 5 A L' 55 To SD (on the page 7-6) A Refer to - for details. Check the items below. The timing belt is not cut. The idle shaft is fixed tightly. The locking screw of the timing pulley is not loose. The key is attached on the spindle. 5 The locking screws of the servo motor are not loose. Gauge Rail Spindle Refer to the drawing above and check the items below. Oil is applied to the spindle. Grease is applied to the gauge rail B WHT BLK C 07 WHT BLK L N A 00V 500VA Amplifier for Servo Motor U V W RED WHT BLK GRN M0 Servo Motor Refer to 7- for details - Check at the display of A amplifier for servo motor. When the display does not show anything, go to step below. When the display shows an alarm of A**, go to step below. When the display shows CL, go to step below.. Refer to the electrical wiring above to check the power circuit from transformer T0 to A.. Follow the [Solution] on the displayed error code A** at section -5, No.5.. Remove the motor cover at the back of the machine, and turn the timing pulley by hand. When you can turn it by hand, replace QPM-95 if the wiring and connection between A and CON9 on QPM-95 are normal. When you cannot turn it by hand, the command from the P.C.B is defective. Replace control P.C.B. QPM-95. -