PowerLine Electric Cutter

Transcription

1 PowerLine Electric Cutter PowerLine Operating Instructions Installation, Operating and Maintenance Instructions PowerLine Models PL2650 and PL2150 Specifications Functional Cut Length x Width (behind blade): 21" EC " x 21" 26" EC " x 26" Cut Height: 2 7/8" Maximum Physical Weight: 21" EC lbs. 26" EC lbs. Shipping Weight: 21" EC lbs. 26" EC lbs. Color: Gray Dimensions: 21" EC 33 3/4"W x 50 3/4"H x 42 3/4"D 26" EC 38 3/4"W x 50 3/4"H x 47 3/4"D Electrical AC Voltage: /240VAC Load Current: Amperes Table of Contents 1.0 Introduction Page Nomenclature Page Controls Page Installation Page The Back Gauge Page Operation Page Maintenance Page Error Codes Page Diagnostic Tests Page Troubleshooting Page 19 Fraction to Decimal Conversion Chart Page 22 Parts Diagrams and Parts Lists Page 23 Wiring Diagrams 1, 2, & Page 29 Serial Number Optional Side Tables WARNING! This machine contains a powered cutting knife which can cause serious or even fatal injury. Never connect power to the machine until you are ready to set up and operate the electric cutter. The AC outlet must be nearby and not blocked. To prevent injury, never place hands or arms under the cutting blade, do not operate the machine with any covers removed or safety features disabled, and cut only paper materials. The front blade guard must be in the lowered position before the clamp or blade will operate. Before attempting any maintenance procedure, be sure power is disconnected and locked out by Martin Yale Industries, Inc. 1

2 1.0 Introduction PowerLine Operating Instructions Thank you for selecting the Martin Yale PowerLine Electric Cutter. PowerLines are designed to provide a high level of safety, accuracy, flexibility, and ease of operation. Each component has been engineered to perform reliably and is 100% factory tested to ensure years of quality service. 2.0 Nomenclature We recommend that you familiarize yourself with the cutter by carefully reading this manual. Reading and thoroughly understanding this manual will help you avoid the most common operational problems and help eliminate operational errors. 1. Chassis - Houses the electrical and mechanical components. 2. Stand - Consists of legs and shelves. The stand can be separated from the chassis. 3. Keyboard Control - 20-character, 2-line Liquid Crystal Display at the top with a keypad below. 4. Right Switch Panel - Contains key switch, clamp switch, and blade switch. 5. Left Switch Panel - Contains On/Off toggle switch, reset switch, and clamp/blade switch. 6. Ready Light - Amber light indicates when safety conditions are met and the machine is ready for the next cutting cycle. 7. Paper Guides - Guide paper and maintains paper position. 8. Rear Safety Cover - Fixed cover over the rear deck. 9. Back Gauge - Controls the movement of paper through the cutting area. 10. Knife - Honed steel blade provides cutting action. 11. Clamp - Secures paper during the cutting process. 2

3 3.0 Controls 3.1 Blade, Clamp, and Power Controls PowerLine Operating Instructions 12. False Clamp - Can be attached to the bottom of the permanent clamp. 13. Cutting Stick - Protects the knife edge at the bottom of the cutting cycle. 14. Leg Levelers - Adjustable feet ensure a level cutting surface. 15. Storage Shelf - Front and rear shelves for operator convenience. 16. Fuseholders - Two fuseholders (located under the front portion of the chassis) contain replaceable power fuses. 17. Circuit Breakers - Resettable circuit protector located under the front portion of the chassis. 18. Shroud - Housing for the blade and clamp drive components. 19. Serial Label - Identifies the serial number, electrical ratings, and agency approvals. 20. Line Cord - Connects the electric cutter to the AC power source. 21. Blade Adjustment - Compensates for blade wear/sharpening. 22. Front Safety Cover - Interlocked front deck cover. 23. Side Tables - Optional accessories to add working surface area to one or both sides AC power on/off toggle switch. Controls power to all circuits. The switch bracket allows insertion of a lock to prevent power activation of the electric cutter. 2. Reset switch - Enables the blade and clamp circuits for the next cutting operation when the blade and clamp are in the up position. Returns the clamp to the up position when only the clamp is used. The ready light will come on when safety conditions are met. (Figure 1, Item 6) 3. Clamp/Blade switch - When pressed simultaneously with the clamp switch (in the right switch panel), the clamp will travel independently of the blade to the clamping position. When pressed simultaneously with the blade switch (in the right switch panel), both the clamp and blade will cycle through the cutting process. 4. Blade switch - When pressed simultaneously with the Blade/Clamp switch (in the left switch panel), both the clamp and blade will cycle through the cutting process. 5. Clamp switch - When pressed simultaneously with the Blade/Clamp switch (in the left switch panel), the clamp will travel independently of the blade to the clamping position. 6. Key switch - Controls power to the blade and clamp. The key can be removed to prevent operation of the blade and clamp. 3.2 Back Gauge Control Panel NOTE: The default language of the back gauge programmable controller is English. The default for movement of the back gauge and subsequent readout is in inches. To change either, see Section Display - During setup, the LCD provides prompts and information. During operation, the LCD provides the cutting length and program status. 3

4 4.0 Installation 2. Longer/Previous - In the manual mode, press this key to move the back gauge away from the cutting area (LONGER). In the automatic mode, press this key to move the back gauge to the last or previous cutting position of the current setup. 3. Shorter/Next - When in the manual mode, press this key to move the back gauge toward the cutting area. When in the automatic mode, press this key to move the back gauge to the next cutting position of the current setup. 4. Speed/Advance - When in the manual mode, press this key to change the back gauge running speed to Fast or Slow. In the automatic mode, press this key to activate the Auto Advance feature. 5. Stop/Undo - When in the setup or programming mode, press the UNDO key to change the selection to the previous choice. Press the STOP key to stop the back gauge from moving. NOTE: The Undo key does not clear an incorrect numerical entry. 6. Number and decimal point Keys - Use these keys to respond to choices offered by the prompts. 7. CE (CLEAR ENTRY) - Press this key to clear an incorrect numerical entry. 8. Set Up - Press this key to enter setup for programming the automatic mode cutting positions. 9. Enter - Press this key to install the operator entries into the operating system, or to review the current setup. 10. Mode - Press this key to toggle the operating mode to manual or automatic, or to select a stored setup. WARNING! To prevent serious personal injury, always use a mechanical lifting device, such as a fork lift or pallet jack, to move the machine or to separate the chassis from the frame. NOTE: Place the cutter on a flat, level foundation sufficient to support its weight. Be sure to allow adequate work space on all sides of the cutter. 4.1 Leveling the Machine Level the cutter (check the top surface in two planes) by adjusting the leg leveler in the bottom of each stand leg. Turn the leg leveler clockwise to shorten the leg length. Turn the leg leveler counterclockwise to increase the leg length. 4

5 4.2 Releasing the Back Gauge To prevent shipping damage, the back gauge is locked in place by two thumb screws(1) located near the ends of the top rear surface of the back gauge. Remove these screws before operating the electric cutter. To do so, first remove the rear safety cover by loosening the crosspoint screws holding the cover to the rear of the shroud and the decks. Remove the two thumb screws that secure the back gauge and reattach the safety 1 cover. 4.3 False Clamp Short Cut When cutting carbonless paper, install the false clamp to help prevent bruising and marking. The false clamp, made from clear polycarbonate, is used to reduce bruising (marking) on carbonless paper. It is not necessary to use the false clamp when cutting standard paper stock. Use of the false clamp affects the minimum cutting distance. When installed, the minimum cutting distance is 2.37". When not installed, the minimum cutting distance is 1.37". Section 6.0, Operation, includes the false clamp set up information. The false clamp is held in place by four (three on the 21" EC) 10/32x3/8 flathead hex socket screws. To install the false clamp, proceed as follows: 1. Turn the on/off toggle switch, located in the left switch panel, to off. 2. Turn the key switch, located in the right switch panel, to off (key vertical). 3. Raise the front safety cover. 4. Locate the position of the screws on the bottom of the false clamp. Install and tighten the screws. 21" False Clamp Screw Location 26" False Clamp Screw Location 4.4 Separating the Stand and Chassis WARNING! To prevent serious personal injury, always use a mechanical lifting device, such as a fork lift or pallet jack, to separate the chassis from the frame. The weight of the chassis is unbalanced. Most of the weight is in the front 2 feet of the chassis. 5

6 4.5 Power Requirements 4.6 Optional Side Tables To separate the chassis from the stand, remove the carriage bolt and acorn nut from the top of each stand leg (see illustration). Lift the chassis from the stand using a mechanical lifting device. To reassemble the stand and chassis, lower the chassis onto the stand and install the carriage bolt and acorn nut through each stand leg. WARNING! The AC power outlet must be installed near the electric cutter and easily accessible. The electric cutter is equipped with a 20 Amp power plug (NEMA #6-20P). This cutter requires a 20 Amp circuit with a 20 Amp receptacle (NEMA #6-20R). Have a qualified electrician install the appropriate branch circuit and receptacle. To install the optional side tables, align the holes in the tables with the screw holes in the side machine chassis. Install and tighten the provided screws. 5.0 The Back Gauge 5.1 General The default language of the back gauge programmable controller is English. The default for movement of the back gauge and subsequent readout is inches. You may change the language by following these instructions: Press the SETUP key as you activate power to the machine. Press the 8 key. The display will show: Configure the System - 8 PowerLine Operating Instructions Choose Configuration 1=Language 2=Units Press the 1 key: Jog Keys to Select Enter for English Press either of the jog keys to scroll through menu options or press the ENTER key for English. You may choose Spanish, Italian, French, German, or English. When the language you require is displayed, press ENTER key. Press UNDO to exit configuration. You may change the units of measure designation by following these instructions: Press the SETUP key as you activate power to the machine. Press the 8 key. The display will show: Configure the System - 8 Choose Configuration 1=Language 2=Units Press the 2 key: Choose Units 1=English 2=Metric Press the appropriate key. English/Metric Units Confirmed Press UNDO to exit configuration. The electronic back gauge can be set at any location from 1.37" from the cut line (2.37" 6

7 with the false clamp installed) to 21.00" or 26.00", depending on the model. While the back gauge can be operated in either a manual or automatic mode, the manual mode is the default mode when you power up the machine. When you power up the machine, the LCD will show the Logo and software revision number, as well as prompting for the false clamp. The back gauge moves to the Home position as part of the initialization routine. When the back gauge position is valid at power up, the LCD will prompt: Back Gauge Free To Move? Hit Enter Key PowerLine Operating Instructions Press the ENTER key and the back gauge moves toward the Home position at the fast speed. If the back gauge position is not valid when power is supplied, the LCD will prompt: Warning! Unknown Back Gauge Position Back Gauge Free To Move? Press the ENTER key and the back gauge moves toward the Home position at Slow speed. In the manual mode, the LCD shows the current back gauge position and the run speed, Fast or Slow. Position the back gauge by pressing the appropriate jog key. Enter a cutting position by pressing the numerical, decimal point and ENTER keys. Change the run speed by pressing the SPEED key. Return the back gauge to the initial position at any time by pressing the CE key followed by the ENTER key. In manual mode, the initial position is at 26" (21" for the 21" Electric Cutter). In automatic mode, the initial position is the first position in the series of programmed positions. In automatic mode, the LCD shows the current position of the back gauge: Position xx.xx Auto Advance: OFF In this mode, the back gauge moves to predefined positions automatically when Auto Advance feature is activated, or semi-automatically when Auto Advance feature is off. To review the predefined positions, press the ENTER key. The predefined cutting positions can be changed. You may cut with the changed positions with or without storing them in the system. There are two methods to enter a predefined position. For the running method, press the jog keys to move the back gauge to the desired position. Press the ENTER key to install the current position. For the key entry method, press the numerical and decimal point keys to select the required position. Press the ENTER key to install the selected position. 6.0 Operation There are two types of predefined positions, fixed and variable. The fixed type uses a starting position and moves the back gauge at a fixed interval automatically when Auto Advance is activated, or semi-automatically when Auto Advance is off. The variable type moves the back gauge to as many as ten distinct positions automatically when Auto Advance is activated, or semi-automatically when Auto Advance is off. Return the back gauge to the first operating position at any time by pressing the CE key, followed by the ENTER key. WARNING! This machine contains a powered cutting knife which can cause serious or even fatal injury. Never connect power to the machine until you are ready to set up and operate the electric cutter. To prevent 7

8 6.1 Supply Power to the Electric Cutter PowerLine Operating Instructions injury, never place hands or arms under the cutting blade, do not operate the machine with any covers removed or safety features disabled, and cut only paper materials. Before plugging in the Electric Cutter power cord, be sure the following conditions have been met: 1. All safety covers are in place. 2. No objects are resting below the cutting area or on the rear decks. 3. The back gauge locking screws have been removed. 4. The power cord will be connected to a 230VAC 20 Amp branch circuit. 5. The On/Off toggle switch is off and that the key switch is off (key vertical). 1. Plug the power cord into a 230VAC 20 Amp outlet. 2. Turn the On/Off toggle switch, (located in the left switch panel) to the on position. The cutting line lights illuminate when power is supplied. 3. Insert the key into the key lock switch (located in the right switch panel) and turn the key to the on position. 6.2 Manual Mode Setup NOTE: The controls were previously discussed in Section 3.0 of this manual. Please refer to Section 2.0 if you have any questions concerning the function of a particular control or key. When the electric cutter is activated, the LCD will briefly show the Martin Yale logo and software revision: (Logo) Martin Yale Smart Back Gauge Rev. xx.xx False Clamp 1 = No or 2 = Yes 1. False Clamp - This selection controls the minimum cutting distance (1.37" without the false clamp or 2.37" with the false clamp). If you have not installed the false clamp, press 1. Back Gauge Free To Move? Hit Enter Key Warning! Unknown Back Gauge Position Back Gauge Free To Move? 2. Is Back Gauge Free to Move? (With valid back gauge position.) or Warning! Unknown Back Gauge Position. Is back gauge free to move? (When back gauge position is not valid.) Press the ENTER key to move the back gauge toward the Home position at the appropriate speed. Position xx.xx Speed: Fast 3. Position: xx.xx Speed: Fast - The display shows the current back gauge position and back gauge speed. Reposition the back gauge by pressing the jog keys, LONGER, SHORTER or by entering a position using the numerical keys, followed by the ENTER key. Change the back gauge speed to slow by pressing the SPEED key. NOTE: As the back gauge moves, the position readout is continuously updated and the selected speed is displayed. When the back gauge stops, the current position and selected speed are displayed. 4. Position the paper stack squarely against the back gauge and either the left or right guides. 8

9 5. Press the RESET button located on the left switch panel. If all safety conditions are met, the amber colored Ready Light will illuminate indicating the machine is ready to cut. NOTE: The front blade guard must be in the lowered position before the clamp or blade will operate. 6. The clamp and blade can be operated simultaneously or independently. To operate simultaneously, press the CLAMP/BLADE switch (on the left switch panel) and the BLADE switch (on the right switch panel). To operate the clamp independently, press the CLAMP/BLADE switch (on the left switch panel) and the CLAMP switch (on the right switch panel). When you are ready to cut paper, press the CLAMP/BLADE switch and the BLADE switch. 7. After the cutting cycle is complete, the Blade and Clamp automatically return to the up position. You may reposition the back gauge (step 6) and make the next cut (step 4). 6.3 Automated Mode Setup NOTE: The controls were previously discussed in Section 3.0 of this manual. Please refer to Section 3.0 if you have any questions concerning the function of a particular control or key. Short Cut For the most accurate cuts, make sure the paper stack is firmly against the left or right guide. When the electric cutter is activated, the LCD will briefly show the Martin Yale logo and software revision: (Logo) Martin Yale Smart Back Gauge Rev. xx.xx False Clamp 1 = No or 2 = Yes 1. False Clamp - This section controls the minimum cutting distance (1.37" without the false clamp, 2.37" with the false clamp). If you do not install the false clamp, press 1. Back Gauge Free To Move? Hit Enter Key Warning! Unknown Back Gauge Position Back Gauge Free To Move? 2. Back Gauge Free to Move? (With valid back gauge position.) or Warning! Unknown Back Gauge Position. Back Gauge Free to Move? (When back gauge position is not valid.) Press the ENTER key to move the back gauge toward the Home position at the appropriate speed. Position xx.xx Speed: Fast Short Cut When cutting carbonless paper, install the false clamp to help prevent bruising and marking. 3. Position: xx.xx Speed: Fast 4. Press the MODE key. 5. Press 1 for Automatic Mode or 2 to Retrieve a Stored Set. Pressing 1 will select the last pre-defined program. The back gauge moves to the first cutting position. When the back gauge stops moving, you can review the program by pressing ENTER. Press 2 to initiate the prompt, Set Number? 1 to 5. When you select a program, the values of that program are displayed. To select a different program, simply enter a new set number. NOTE: Your PowerLine Cutter has been factory programmed for test purposes. You may reprogram the settings by following instructions in Sec

10 6.4 Programming the Back Gauge When the required setup is indicated, press the ENTER key. The display will show: Position: xx.xx Auto Advance OFF The Auto Advance feature will automatically move the back gauge to the next programmed position. To select Auto Advance, press the SPEED key. NOTE: The front safety cover must be in the lowered position before the clamp or blade will operate. The back gauge moves to the first cutting position. To verify the setup, move the back gauge through the pre-defined program positions by pressing the Next or Last keys. 6. Position the paper stack against the back gauge and either the left or right guides. Press the Reset switch (1). Lower the front safety cover. If all safety conditions are met, the amber colored Ready Light illuminates indicating the machine is ready for the cutting cycle. The clamp and blade can be operated simultaneously or independently. To operate simultaneously, press and hold the CLAMP/BLADE switch (2) and the Blade switch (3). To operate the clamp independently, press and hold the CLAMP/BLADE switch (2) and the Clamp switch (4). When you are ready to cut paper, press and hold the CLAMP/BLADE switch and the Blade switch. After the cutting cycle is complete, or if you release the push buttons simultaneously, the clamp and blade return to the up position. If you release either of the push buttons singly, the blade and clamp will stop, then return to the up position when the the other push button is released. After the initial cut, press the NEXT key to advance the back gauge to the next programmed position. Make the next cut by following previous instructions. If the Auto Advance feature has been activated, the back gauge will automatically move to the next programmed position after each cut. If Auto Advance is not active, push the NEXT key to move the back gauge to the next programmed position after each cut Programming Fixed Back Gauge Positions Fixed cutting programs are useful for cutting a series of identical stacks from a larger stack. A fixed cutting program moves the back gauge toward the cut line in identical intervals. (See diagram.) To define and store a fixed cutting program in your cutter: 1. Activate the cutter by turning the ON/OFF toggle switch and key switch to the on position. Answer the false clamp prompt. 2. After the Back Gauge Position and Speed are displayed, press the SETUP key to change the system to the automatic mode. Define a New Set of Positions 3. Press 1 on the keypad. Choose Type of Set 1= Fixed 2= Variable PowerLine Operating Instructions Fixed cutting programs start at a programmed point and move the back gauge by a fixed interval after each cut. Initial Position? Enter Value or Jog 4. At the display prompt, select either 1) the running method or 2) the key entry method. Position: xx:xx Speed: Fast 10

11 If you select the running method, press the jog keys to position the back gauge to the required starting location and then press the ENTER key. If you select the key entry method, enter the back gauge starting position by pressing the appropriate numerical and decimal point keys. Press the ENTER key to install the selected position. Initial Position Installed Interval Amount? Enter Value 5. At the display prompt, press the numerical and decimal keys to enter the required dimension. Short Cut Store settings for the jobs you ll need most often as one of your cutter s 5 programs. Both variable and fixed programs can be stored in your cutter s memory. Enter Position xx.xx Inches Press the ENTER key to install the interval. Fixed Set Installed Store This Set? 1=No 2=Yes 6. At the display prompt, press 1 to not store the positions. (Unstored positions are deleted when cutter power is interrupted or switched off.) After this selection, the back gauge moves to the first cutting position. Verify the positions by pressing the NEXT key. To return the back gauge to the first operating position, press the CE key followed by the ENTER key. 7. Press 2 to store this program in your PowerLine s memory, where it will remain until you alter it. Set Number (1-5)? To Be Updated 8. Your PowerLine Cutter can store up to five (1-5) programmed cutting sequences. Press the appropriate number on the keypad to store this set. Programmed Set Number x Updated 9. The back gauge moves to the initial cutting position and the cutter changes to the automatic mode. You may begin to cut Programming Variable Back Gauge Positions Variable cutting programs are useful for cutting a series of non-identical stacks from a larger stack. A variable cutting program moves the back gauge toward or away from the cut line in intervals that you program according to the following instructions: 1. Activate the cutter by turning the ON/OFF toggle switch and key switch to the on position. Answer the false clamp prompt. 2. After the back gauge Position and Speed are displayed, press the SETUP key to change to the automatic mode. Define a New Set of Positions Choose Type of Set 1=Fixed 2-Variable Variable cutting programs start at a programmed point and move the back gauge by varying intervals after each cut. 3. Press 2 on the keypad. Position 1? Enter Value or Jog 4. At the display prompt, select either 1) the running method or 2) the key entry method. If you select running method, press the jog keys to move the back gauge to the required first cutting position. Press the ENTER key to install the current position. 11

12 Position 1 Installed Position 2? Enter Value or Jog Repeat this procedure for up to ten entries. If you select the key entry method, press the numerical and decimal point keys to enter the first position. Press the ENTER key to install the position. Position 1 Installed Repeat this procedure for up to ten entries. In either running method or key entry, press the ENTER key to end the entry procedure (if less than ten positions are desired). Variable Set Installed Store This Set? 1=No 2=Yes Short Cut Store settings for the jobs you ll need most often as one of your cutter s 5 programs. Both variable and fixed programs can be stored in your cutter s memory. 5. At the display prompt, press 1 to not store the positions. (Unstored positions are deleted when cutter power is switched off.) After this selection, the back gauge will move to the first cutting position. Verify the positions by pressing the Next key. To return the back gauge to the first operating position, press the CE key followed by the ENTER key. 6. Press 2 to store this program in your PowerLine s memory, where it will remain until you alter it. Set Number (1-5) To Be Updated 7.0 Maintenance 7.1 Blade Removal 7. Your PowerLine Cutter can store up to five (1-5) programmed cutting sequences. Press the appropriate number on the keypad to store this set. Programmed Set Number x Updated 8. The back gauge moves to the initial cutting position and the cutter changes to the automatic mode. You may begin to cut. WARNING! This machine contains a powered cutting knife which can cause serious or even fatal injury. Never connect power to the machine until you are ready to set up and operate the electric cutter. To prevent injury, never place hands or arms under the cutting blade, do not operate the machine with any covers removed or safety features disabled, and cut only paper materials. Before attempting any maintenance procedure, be sure power is disconnected and locked out. WARNING! The cutting blade is extremely sharp. Serious bodily harm can result from mishandling. NOTE: To prevent dulling the knife, do not let the knife edge contact any surface except the cutting stick or blade carrier. 1. Activate machine power. Lower the cutting blade as if you are cutting paper. Turn off the ON/OFF toggle switch when the blade contacts the cutting stick. Turn the key switch to the OFF position (key vertical). 2. Remove the far right blade retaining screw. 1 CAUTION: Do not operate the blade or clamp with the blade holder tools attached to the blade. Extensive equipment damage can occur. 12

13 3. Turn the ON/OFF toggle switch and key switch to the ON position so that the blade and clamp will return to the up position. Turn the key switch to the OFF position (key vertical). Remove the two center blade retaining screws. Install and securely tighten the blade holder tools. WARNING! When you loosen the blade holder tools, the blade will be free to fall from the carrier. Make sure your have a firm grip on the blade holder tools. 7.2 Blade Installation 4. Loosen the remaining blade retaining screws. Slightly loosen the blade holder tools slightly and carefully lower the blade from the blade carrier. 5. Move the blade to the right side and pull the left side of the blade toward the front of the machine. Now remove the right side of the blade. 6. Secure the blade so the sharp edge will not be exposed and remove the blade holder tools. WARNING! The cutting blade is extremely sharp. Serious bodily harm can result from mishandling. NOTE: To prevent dulling the knife, do not let the knife edge contact any surface except the cutting stick or blade carrier. A newly sharpened or new blade will require adjustment for proper cutting, see Section Blade Adjustment Turn the ON/OFF toggle switch and key switch off (key vertical). 2. Install the blade holders in the two center blade mounting holes so that 1/4" to 5/16"(1) of thread is visible between the blade and blade holder. 3. Lifting with the blade holders, carefully place the blade into the blade carrier and securely tighten the blade holders. 4. Starting from the left end of the blade, insert and tighten two of the five blade screws. Remove the blade holder tools and install and tighten the two blade retaining screws in their place. To insert the far right blade screw, turn the ON/OFF toggle switch and key switch on. Lower the blade using the blade switches, turn the ON/OFF toggle switch and key switch off (key vertical) when the blade reaches a position low enough to access the remaining blade screw hole. Insert and tighten the remaining screw. 5. Switch the ON/OFF toggle switch and key switch on so that the blade will travel to the up position. NOTE: When properly adjusted, the entire length of the blade should cut cleanly through the last sheet of the stack. How deeply the blade indents the cutting stick depends on blade condition. Remember to adjust the blade position only to the depth needed to cut cleanly through the last sheet of the stack. WARNING! The blade must be adjusted so the cutting edge is above the bottom edge of the clamp when both are in the full-up position. Due to normal blade wear, sharpening, or blade replacement it will be necessary to adjust the blade position. Blade adjustments control height and levelness. There are three areas where the adjustments are made. (1) The blade screw holes in the blade carrier are slotted so the blade can be move up/down in the carrier. (2) The blade height adjustment is accessible through the right side chassis panel. (3) The leveling adjustment set screws located in the top of the blade carrier. The following procedure includes the removal of the shroud and complete adjustment of the blade. 13

14 WARNING! The cutting blade is extremely sharp. Serious bodily harm can result from mishandling Disconnect power and remove the shroud. A. Remove the two thumb knobs. One is at the bottom of the keyboard control panel. The other is located on the left front shroud. B. Remove the two screws at the bottom rear of the shroud. C. Remove the two screws from the top rear of the keyboard control panel. Separate the control panel from the shroud and carefully disconnect (pull) the ribbon cables (1) from the rear of the keyboard control panel. Feed the cables through the hole in the shroud. D. Slide the shroud toward the front of the machine so the ready light is separated from the shroud. E. Lift the shroud and rear safety cover from the electric cutter. Carefully reconnect the cables to the rear of the keyboard control panel. 2. Make sure the blade is in the highest position (top of blade carrier slots). If necessary, install and tighten the blade holders as instructed in Sections 7.1 & 7.2. Loosen the blade retaining screws and move the blade to the top of the slot. (The blade must be lowered to access the far right blade screw.) Retighten the blade retaining screws. Remove the blade holders and install and tighten the two blade retaining screws in their place. 3. With the blade in the up position, measure the distance from the top of the blade carrier to the cutting stick. The distance should be 9 3/8". If necessary, adjust the blade adjustment screw (accessible through the right side chassis panel) until the distance is correct. 4. Activate power, lower the blade to the lowest cutting position and turn off the On/Off toggle switch. Again measure from the top of the blade carrier to the cutting stick. The distance should be 6 1/16". If necessary, raise the blade to its highest position in the carrier and repeat step Place a 1/4" stack of paper over the entire length of the cutting stick and initiate the cutting cycle. If the blade cuts evenly through the last sheet of paper and just slightly into the cutting stick, no further adjustment is necessary. If the last sheet is not cut evenly through, proceed as follows: A. Loosen the blade retaining screws so they securely hold the blade in position, but will allow movement when turning the blade leveling set screws. B. Adjust the blade leveling set screws clockwise in 1/4 turn increments and test cut until the bottom sheet of paper is cleanly cut with the blade cutting slightly into the cutting stick. If the blade cannot be adjusted for a correct cut using the blade leveling set screws, slide the blade to a lower position in the blade carrier slots and repeat the leveling adjustment. 6. After the blade has been adjusted for a correct cut, disconnect power and remove the front deck. 7. Inspect the trunnion gears on the blade adjustment shaft to ensure the gears are meshing in the center. If necessary, adjust the shaft collars to obtain the proper gear mesh. 8. Reinstall the front deck and carefully disconnect (pull) the cable from the rear of the keyboard control panel. 9. Reinstall the shroud, carefully feeding the cable through the hole in the shroud. 10. Carefully reconnect the cable to the rear of the keyboard control panel and mount it onto the shroud. 11. Reinstall the thumb screws and rear deck screws to secure the shroud. 7.4 Clamp Height Adjustment NOTE: The bottom edge of the clamp should always be approximately 1/8" lower than the sharp edge of the blade. 14

15 WARNING! The cutting blade is extremely sharp. Serious bodily harm can result from mishandling. The paper clamp height should be adjusted so the bottom of the paper clamp is always approximately 1/8" below the blade edge when both are in the maximum up position. To adjust the clamp height: lower the paper clamp (only). Loosen the two hex key buttonhead screws on the paper clamp limit switch bracket. Note: The slotted screw hole in the bracket allows vertical adjustment. If the clamp is above the bottom (sharp edge) of the blade, lower the clamp limit switch bracket slightly and tighten the bracket retaining screws. Raise the clamp and check. Repeat until the clamp is approximately 1/8" below the blade. If the clamp is too far below the edge of the blade, raise the paper clamp limit switch bracket. Check clamp height and repeat, if necessary. Note: Always securely tighten the bracket retaining screws. PowerLine Operating Instructions 7.5 Cutting Stick Rotation The design of the PowerLine cutting stick allows rotation to eight cutting locations. (The stick may be rotated to four surfaces and reversed from end to end.) To rotate the stick proceed as follows: 1. Turn off power to the cutter and raise the front cover. Turn the key switch to the off position (key vertical). 2. Carefully lift up one end of the cutting stick. 3. Place a flat tipped screwdriver under the raised end of the cutting stick and slide it under the length of the stick to completely remove it from the channel. 4. Rotate the stick to a new surface and place it back into the channel. When all four surfaces have been used, reverse the stick end to end and repeat the rotation process as needed. Replace the stick when a correctly adjusted new, or resharpened blade will no longer cut completely through the bottom sheet of a stack. 7.6 Back Gauge Squaring Adjustment If the cutting distance is not within 1/64" from one end of the back gauge to the other, proceed as follows: 1. Loosen the hex head bolt that secures the back gauge to the slider block (top rear center of the back gauge). 2. Loosen or tighten the socket head screws on the rear side of the back gauge as follows: A. Cut paper at each end of the back gauge to determine which end needs to move closer to the cutting area. Slightly loosen the socket head screw on the corresponding side. Slightly tighten the socket head screw on the opposite side. B. Recheck the back gauge squareness by cutting paper positioned at each end of the back gauge. C. Repeat the adjustment as necessary and retighten the hex head bolt. 7.7 Back Gauge Slider Block Adjustment 1. Position the back gauge to approximately 20". 2. Turn off power by turning the key switch to off (key vertical) and unplug the power cord from the power outlet. 3. Remove the lower rear cover. First move the screws/nuts joining the lower front and rear covers. Then remove the cross point screws that secure the lower rear cover to the chassis. Allow the lower rear cover to drop until it clears the lower front cover. Pull the lower rear cover forward and set it aside. 15

16 4. There are four screws that secure the nut plate assembly to the front of the slider block. The bottom 2 screws are socket head cap screws, one of which also secures a lock washer. The top 2 are cross point screws. Loosen only the cap screw with the lock washer. 5. The adjustment system is a push/pull arrangement that features Two hex socket screws extend approximately 1/4" from the side of the block. The other two screws extend through the block and are secured by two nuts. Slightly loosen the front socket head cap screw that extends from the side of the slider block. Slightly tighten the other front socket head cap screw that is threaded into the opposite side of the slider block. Tighten the screw until a slight resistance/bind is felt when manually moving the back gauge. Next, slightly loosen the rear socket head cap screw that extends from the side of the slider block. Slightly tighten the other rear socket head cap screw that is threaded into the opposite side of the slider block to obtain smooth movement of the back gauge with no binding. Verify that the back gauge end play is minimal. 6. Retighten the cap screw on the slider block nut plate. 7. Slowly operate the back gauge the full length of travel. Verify that the back gauge does not bind or stall. Repeat the slider block adjustment if necessary. 8. Reinstall the lower rear cover. 9. Reapply power to the cutter. 7.8 Back Gauge Calibration The location of the back gauge is referenced from the Home position. Home position is determined during the homing cycle when the homing flag (located on the back gauge slider block, pg.28) enters and activates the homing sensor (mounted at the rear of the chassis). When this happens, the read-out is reset to on the Model 2650 and on the Model If the back gauge is not at this distance from the cut point (blade), all cuts made will be off the same amount. To calibrate the back gauge, proceed as follows: 1. Determine if the stock is being cut too short or too long. If the cut is too short, the Home flag must be moved toward the cutting blade. If the cut is too long, the Home flag must be moved away from the cutting blade. Determine the exact distance the cut is off. This is the distance the home flag will need to move. 2. Position the back gauge to approximately Switch the ON/OFF toggle switch, located in the left switch panel, to the OFF position. Turn the key lock switch, located in the right switch panel, to the OFF (Vertical) position. 4. Remove the lower rear cover. First remove the screws and nuts joining the lower covers. Next remove the six screws that secure the cover to the chassis. Lower the rear cover and set it aside. 5. Mark the initial position of the Home flag on the side of the slider block for reference. Slightly loosen the two screws that hold the Home flag to the slider block. Slide the Home flag the direction and distance determined in step 1. Retighten the Home flag screws. 6. Switch the ON/OFF toggle switch to the ON position. Answer the prompts so that the back gauge will go to the Home position. 7. Check the accuracy of the adjustment by cutting a sheet of paper and precisely measuring the cut sheet. The cut length should be within.01 of the back gauge position (reading). If not repeat this procedure starting with step 1. NOTE: The back gauge must be Homed each time the Home flag is moved by turning the power OFF and ON. 8. When the correct calibration is achieved, re-install the lower rear cover and return the machine to operation. 7.9 Lubrication The mechanical components of the cutter require periodic lubrication depending upon 16

17 cutter use. A 30W oil, lithium-based grease, and 90W gear oil are the recommended lubricants. Grease points should be cleaned and lightly recoated. Screws, pivot points, and Oilite bearings should be cleaned and lightly oiled. The gear box should be drained and refilled. Heavy use is 8,000 or more cutting cycles per week. Moderate use is 4,000-8,000 cutting cycles per week.this schedule is based on heavy use. 8.0 Error Codes Part Frequency Lubricant Tower Rails (1) Every blade change/monthly grease Clamp drive screw (2) Every blade change/bi-monthly 30W oil Clamp thrust bearing (3) Annually grease Clamp gear lever pivot pin (4) Every blade change/monthly 30W oil Clamp guides (5) Every blade change grease Crank gear/gear box gear (6) Bi-monthly grease Gear box (7) Annually 90W oil Back gauge Acme screw (8) Monthly 30W oil All Oilite bearings (9) Annually 30W oil Limit switch bracket pivot pts. (10) Annually 30W oil If the machine control circuitry senses a malfunction, a numerical error code is displayed on the keyboard control panel. There are seven possible error codes. If an error code is displayed, it may be helpful to use the resident diagnostic tests. The tests are explained in Section 10. If a problem develops, error codes help you analyze what the problem is! Error Code 10 (err 10) Error Code 11 (err 11) Error Code 12 (err 12) Error Code 19 (err 19) Error Code 30 (err 30) Error Code 31 (err 31) No detection of the back gauge home flag. The back gauge position is too far positive. The back gauge position is too far negative. No detection of the encoder disk pulses. Indicates a data verification error in the non-volatile memory of the control circuitry. Indicates a data access error in the non-volatile memory of the control circuitry. 9.0 Diagnostic Tests The electric cutter program provides 9 diagnostic tests to assist in analyzing back gauge performance. NOTE: These tests should only be performed by a qualified service technician. There are two ways to initiate diagnostic tests. The most convenient is to press the SETUP key as you activate power to the machine. (An alternate method is to remove the front deck and press the small push button located in the center of the main logic board.) In either case, the keyboard control panel will display: Diagnostics Tests Depress 1-9 To enter a particular test, press the corresponding numerical key for that test. Stop any test by pressing the STOP key. Press the UNDO key to return to the diagnostic entry screen. To exit the diagnostic test mode, press UNDO a second time. Diagnostic Test 1 NOTE: Perform this test only when you suspect a memory error has 17

18 occurred. The actual memory values can be obtained from Martin Yale Technical Assistance ( ). Use this test to view the values stored in the non-volatile memory RAM (Random Access Memory). Press the SHORTER key to step through the value of each memory location. 1-Non Volatile Ram Test xx FF Address Value The data display is in the hexadecimal format. The display shows the address (the location in memory), and the value (the data stored in the selected address). Diagnostic Test 2 2-Inputs and Keypad Test SW Blde Clamp Use this test to check the functionality of the keypad keys, the clamp and blade sensor and the small push button switch on the main logic board. To test the keypad, press each key, except the UNDO, one at a time. The display should report the key that was depressed. Diagnostic Test 3 3-Manual Movement of Back Gauge Mode Key to Change Movement Mode Use this test to check the functionality of the back gauge motors and the movement of the back gauge. While in this test press the MODE key to select AC motor only, stepper motor only, or both motors. Use the Jog Keys to Run the Motors AC Motor Only WARNING! During this test, the system does not automatically switch to slow speed when it gets close to either end of the drive shaft. Use caution when moving the back gauge at high speed to prevent a damaging collision. The stepper motor moves the back gauge at slow speed. The LONGER and SHORTER keys move the back gauge in the direction selected. Diagnostic Test 4 4-Stepper Motor System Test Home Current Phase xx xx xx This test checks the functionality of the stepper motor and the back gauge home flag sensor. The keyboard control display will show: The Home value will be 1 only when the home sensor is blocked by the back gauge flag. The Current value changes with different power level selections. (The stepper motor can be enabled at three different power levels, 1/3, 2/3, or full power.) The Phase value changes as the motor turns. The following keys are used in this test: 1 Key Sets the stepper motor power The current value should be 10. level to 1/3. 2 Key Sets the stepper motor power The current value should be 01. level to 2/3. 3 Key Sets the stepper motor power The current value should be 00. level to full. 4 Key Each press single steps the back gauge away from the blade. 18

19 5 Key Each press single steps the back gauge toward the blade RUN Key Turns the fast motor to move away from the blade. PowerLine Operating Instructions STOP Key Turns off the fast motor and The current value should be 11. the stepper motor. MODE Key The slow motor moves the When Home position is back gauge away from the reached, the Home value blade to the Home position. should be 1 and the Current value should be 11. Diagnostic Test 5 5-Define Start Position Start Position? _. This test is used to define the back gauge limit positions. The prompt will guide you through this procedure. The start position is always 1.37". The home position will be 21.00" for model PL2150 and 26.00" for model PL2650. Diagnostic Test 6 6-Internal Ram Test xx xx Address Value Checks memory values and is beyond the scope of the maintenance procedure. Diagnostic Test 7 This test performs a back gauge cycle test for functionality. The back gauge automatically moves through the following positions: (Home for 26" EC); (Home for 21" EC); 16.00; 11.00; 6.00; 1.37; 6.00; 11.00; 16.00; (Home for 21" EC); (Home for 26" EC). 7-Cycle Back Gauge Cycle Count xx:xx Position xx:xx To pause or stop the test, press the STOP key to stop the test. Press the SPEED key to restart the test. Press the UNDO key to return the system to the diagnostic entry screen. Diagnostic Test 8 Diagnostic Test 9 This test allows the selection of one of five languages and the units of measure. The default language of the back gauge programmable controller is English. The default for movement of the back gauge and subsequent readout is in inches. To change either, see Section 5.0. This test checks the alignment of the encoder disk and measures the duty cycle of each channel used by the encoder circuitry. To begin the test, position the back gauge approximately 3" from the blade using the LONGER and SHORTER keys as required. 9-Encoder Alignment Test Press the SPEED key to start the test. The slow motor moves the back gauge further away from the blade. The system samples a measurement every 1/2 second while the motor runs. If an error is detected during the measurements, the test stops and the dis - play shows the message: Alignment Error Number x Auto Measure Depress Speed Key X represents an error number (1-5). Error messages 1-4 identify a problem with the 19

20 detection of encoder disk teeth. Error message 5 identifies an encoder disk direction of rotation error. At the end of a measurement, the duty cycle of channel 1 and 2 is displayed as well as their phase relationship. The display shows the message: D1 D2 Phase xx% xx%.xx PowerLine Operating Instructions NOTE: The test will stop if the Home position is sensed. The following keys are functional during this test: STOP Turns off the motor. 1 Re-displays the entire message. 2 Displays the duty cycle of channel 2. 3 Displays the phase difference between channel 1 and Troubleshooting Following is a list of possible problems and their recommended solutions. If you encounter a problem not on the list or if the recommended solution does not solve the problem, contact Martin Yale for technical assistance ( ). Problem Solutions 1. The bottom sheet of a paper Rotate the cutting stick. Check the blade stack is not cut. adjustment. Make sure the blade cuts slightly into the cutting stick. Sharpen or replace the blade. (See Sections 7.) 2. The bottom sheets of paper Check the blade adjustment. Make sure it are only partially cut. is level and cuts slightly into the cutting stick. Check the cutting stick to make sure it is not bowed. (See Section 7.) 3. The electric cutter will not Make sure the power cord is plugged into power up. a 20 Amp (NEMA #6-20R) receptacle. Check the 2A (F1) input power fuse. Replace, if necessary. Check the key switch to make sure it is in the on position. (See Section 4.) 4. The blade will not operate. Reset the 12 Amp circuit breaker. Check to make sure the key switch is in the on position. Make sure both blade switches are being pressed at the same time. Press the reset button and make sure the ready light is on. Make sure the back gauge is not moving. (See Sections 2, 3, 4, 6.) 5. The clamp will not operate. Reset the 7 amp circuit breaker. Make sure the key switch is in the on position. Press the reset button and make sure the key switch is in the on position. Make sure both clamp switches are being pressed at the same time. Press the reset button and check to make sure the ready light is on. Make sure the back gauge is not moving. (See Sections 3 & 6.) 6. The ready light is not on. Press the reset button. Make sure the back gauge is not moving. (See Section 2, 3, & 6.) 20

21 7. The blade stalls. The blade is dull. Sharpen the blade. The dull blade may have caused the thermal protection of the blade drive motor to stop the motor, Make sure the blade drive cooling fan is operating. (See Sections 6 & 7.) 8. The clamp will not raise Too much paper has been loaded which after the first cut. has disabled the upper clamp limit switch. (See Section 6.) 9. No cutting line. Make sure power is on. Check the 2 Amp fuse (F1). Replace, if necessary. Check the circuit breaker and reset, if necessary. Check the light bulbs and replace, if necessary. (See Sections 2, 4, 6, & 7.) 10. The back gauge won t move Check the blade limit switches. Reset, if in the fast mode. necessary. Check the 2 Amp Slo Blo back gauge fuse (F2) and replace, if necessary. Run diagnostic test 3. (See Sections 2, 3, 5, 6, & 9.) 11. The back gauge will not Check the 7 Amp circuit breaker and reset, move. if necessary. Check the 2 Amp Slo Blo back gauge fuse (F2) and replace, if necessary. Run diagnostic tests 4 and 7. (See Sections 3, 5, 6, & 9.) 12. An error code 10 (err 10) The back gauge home flag is not entering the is displayed. sensor. Reset the 7 ampere circuit breaker; run diagnostic test 4. (See Sections 3, 5, 6, & 9.) 13. An error code 19 (err 19) The back gauge is not moving. Check the is displayed. 7 ampere circuit breaker and reset, if necessary. Run diagnostic tests 4, 7, and 9. (See Sections 3, 5, 6, & 9.) 21

22 Fraction to Decimal Conversion Chart PowerLine Operating Instructions 22 Fraction 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Decimals Millimeters Fraction 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 Decimal Millimeters

23 Cutter Assembly Item Part Number Qty. Description 1. M-O Cutting Stick (21" EC) M-O Cutting Stick (26" EC) 2. W-O Housing (21" EC) W-O Housing (26" EC) 3. W-O Left Rear Deck (21" EC) W-O Left Rear Deck (26" EC) 4. W-O Back gauge (21" EC) W-O Back gauge (26" EC) 5. W-A Rear Safety Cover Assy (21" EC) W-A Rear Safety Cover Assy (26" EC) 6. W-O Right Rear Deck (21" EC) W-O Right Rear Deck (26" EC) 7. W-O Control Box 8. M-S Leg Leveler 9. M-S / /4" Carriage Bolt M-S Acorn Nut Item Part Number Qty. Description 11. M-O Front Safety Cover Panel M-O Front Safety Cover Panel 12. W-O Left End Cover 13. W-O Right End Cover Not Illustrated: M-S Front Safety Cover Interlock Switch M-S Bumper W-O Bumper Bracket W-O Switch Cover W-O Brake Cover 10. W-O Front Deck (21" EC) W-O Front Deck (26" EC) 23

24 Control Panels PowerLine Operating Instructions Item Part Number Qty. Description 1. M-S On/Off Toggle Switch, 220VAC 2. M-S Momentary Push button Switch 3. M-S Momentary Push button Switch 4. M-O Left Control Panel Housing 5. M-O Right Control Panel Housing 6. M-S Keylock Switch T-Frame Assembly Item Part Number Qty. Description 1. M-S /8"-16x3 1/2 Bolt 2. M-S /4"-20x1 1/4" Hex Hd Bolt M-S /4"ID Split Lock Washer 3. W-O Tower Tie Bar (21" EC) W-O Tower Tie Bar (26" EC) 4. W-A Right Rear Tower Ass y 5. W-A Right Front Tower 6. W-I Rear Deck Spacer (21") W-I Rear Deck Spacer (26") 7. W-I Front Deck Spacer (21") W-I Front Deck Spacer (26") 8. W-O OD X Spacer 9. W-O Gib Adjuster 10. W-O Left Front Tower 11. W-G Gib Plate 12. M-S /4"x1" Dowel Pin 13. M-S /8"-16x1" Hex Hd Bolt M-S /8" USS Split Lock Washer 14. W-W T-Frame Base (21") W-W T-Frame base (26") 15. W-O Tower Rail 16. M-S /16-18 X 3/4 Socket H.D.Screw 17. W-A Left Rear Tower Ass y 24