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660P
Maintenance Manual
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Duplo 660P Maintenance Manual

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Page 1
MAINTENANCE
MANUAL
PAPER CUTTER
660P
Copyright © 2000 Duplo USA Corporation
P/N 660PSMV2
ALL RIGHTS RESERVED
Page 2
Page 3
TABLE OF CONTENTS
Section 1 - Specifications
Section 2 - Maintenance & Mechanical Adjustments
Lubrication ............................................................................................................ 2-2
Main Worm Gear and Drive Block ........................................................... 2-2
Knife and Clamp Guides .......................................................................... 2-2
Hydraulic Oil ............................................................................................ 2-2
Blade Sharpening .................................................................................................. 2-2
Removal and Installation of the Cutting Tables ........................................................ 2-3
Cutting Table Squareness ...................................................................................... 2-4
Cutting Table Alignment ......................................................................................... 2-4
Backgauge Alignment ............................................................................................ 2-5
Cutting Accuracy .................................................................................................. 2-5
Section 3 - Troubleshooting
Troubleshooting Tables ........................................................................................... 3-2
Section 4 - Hydraulics
Hydraulic Adjustments ........................................................................................... 4-2
Hydraulic Diagram................................................................................................. 4-4
Section 5 - Electrical Description & Adjustments
Start Up and Shut Down Procedure....................................................................... 5-2
Set Up for Programmatic MKII............................................................................... 5-3
Option Settings Table ............................................................................................. 5-4
Rear Calibration Point (Cutting Accuracy)............................................................. 5-5
PLC Input/Output Table .......................................................................................... 5-6
Main Electrical Diagram Key ................................................................................. 5-7
PLC Electrical Diagram ......................................................................................... 5-8
Programmatic MKII Panel Circuit Diagram ............................................................ 5-9
Backgauge Motor Drive Circuit Diagram ............................................................... 5-9
IMPORTANT THIS DEVICE MUST BE OPERATED WITHIN THE SPECIFIED AC LINE VOLTAGE. IF THE AC POWER FALLS OUTSIDE OF THE SPECIFIED LIMITS, A DEDICATED POWER LINE MUST BE USED. IF THE POWER STILL DOES NOT FALL WITHIN SPECIFIED GUIDELINES A POWER CONVERSION (BUCK/ BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT IN POOR OR NO OPERATION.
Page 4
IMPORTANT NOTICE
The Duplo 660P paper cutting guillotine which you have received has been thoroughly inspected and tested.
Please Note:
Please ensure that all service personnel read these instructions thoroughly before working on the 660P.
1. Power guillotines must be serviced only by trained and reliable persons.
2. Defects and damage on cutting machines which affect the safe operation must be dealt with immediately.
Until ALL faults have been corrected, the cutter must not be operated.
3. Regular inspection of all safety devices must be made.
4. Transportation of guillotine knives should only be allowed in the specially designed wooden carrying
cases supplied.
5. To prevent serious injury only one person may operate the machine at a time.
* The use of this machine is limited to cutting paper and chip board only.
SAFETY
Page 5
SECTION 1
SPECIFICATIONS
Page 6
SECTION 1 - SPECIFICATIONS
GENERAL
Cutting Width ......................................................................... 26.5”
Maximum Paper Pile Height ................................................... 3.93”
Minimum Cut Size without False Clamp .................................. 0.79”
Minimum Cut Size with False Clamp ...................................... 2”
Maximum Length (back table) ................................................ 26.5”
Minimum Clamp Pressure ...................................................... 300 lbs.
Maximum Clamp Pressure ..................................................... 2,500 lbs.
Programmable Memory Settings ............................................ 9
Weight ................................................................................... 1,124 lbs.
Operating Temperature ........................................................... 32 - 131 °F
Operating Humidity ................................................................ 45 - 85 % Relative Humidity
Knife Tip Angle....................................................................... First Bevel 22° Second Bevel 24°
Fluids
Hydraulic Fluid ....................................................................... Type ISO 68 & 32
Lubricating Oil ........................................................................ SAE 30 & 40
POWER REQUIREMENTS
Voltage ................................................................................... 220 - 240 VAC
Phase .................................................................................... Single
Current .................................................................................. 20 Amperes
DIMENSIONS
Length .................................................................................... 63”
Width ..................................................................................... 60”
Height .................................................................................... 57”
Table Height ........................................................................... 34.64”
* Specifications subject to change without notice
660P Cutter
1 - 2
Page 7
SECTION 2
MAINTENANCE
&
ADJUSTMENTS
Page 8
SECTION 2 - MAINTENANCE & ADJUSTMENTS
There are several locations that require periodic oil or grease applications. The motors, however, have high quality sealed bearings that do not require lubrication.
OILING THE MAIN WORM GEAR AND DRIVE BLOCK
Perform this procedure approximately every three months.
1. Fill the automatic oiling cup (located on the top
right of the main portion of the cutter) halfway with a high quality machine oil.
2. Adjust the flow to allow one drop of oil every one
second.
3. Use the MKII controller to move the backgauge
it’s maximum limits of forward and reverse travel.
2. Turn the green knife change switch to the right (knife change position).
3. Press and hold both yellow cut push-buttons. The clamp and knife will drop down and stay in the down position.
4. Apply grease to the remaining surfaces.
5. Turn the knife change switch to the left.
HYDRAULIC OIL
Due to the hydraulic circuit’s limited duty cycle, the oil should last for the life of the machine. However, if there was a leak, top off the hydraulic oil as indicated by the sight glass located behind the front panel on
4. Turn off the flow of oil when the worm gear is thoroughly oiled.
5. Add more oil and repeat the process if the worm gear appears to be dry.
KNIFE AND CLAMP GUIDES
Perform this procedure as necessary.
1. Remove the front cover.
2. Apply grease to all exposed areas of the guide surfaces.
the oil reservoir.
BLADE SHARPENING
The cutting blade requires sharpening and must not be neglected. Several symptoms may be present indicating the blade must be sharpened or replaced.
Signs that the cutting blade requires sharpening:
1) Loud sound while blade cuts paper
2) Paper “tears” rather than makes clean cuts
2) Knife won’t cut thick stacks of paper
3) Cutter beeps while cutting paper Sharpening specification: 22° with 2° second bevel
660P Cutter
2 - 2
Page 9
SECTION 2 - MAINTENANCE & ADJUSTMENTS
REMOVAL AND INSTALLATION OF THE CUTTING BED
WARNING
THE CUTTING TABLES ARE VERY HEAVY. IMPROPER HANDLING MAY CAUSE SERIOUS INJURY. USE EXTREME CARE WHILE PERFORMING THIS PROCEDURE.
DISASSEMBLY
1. Remove the front lower cover.
2. Remove the back lower cover.
3. Remove the backgauge drive cover.
4. Remove the plastic wheel (used for fine adjustments).
5. Cut and remove all of the wire ties located underneath the right side of the cutting table.
6. Remove the two bolts securing the cutting buttons cover. They are located on the underside of the cutting table.
10. Using an assistant, remove the front table and CAREFULLY set it aside.
11. Remove the two vertically oriented bolts holding the rear table to the main frame.
12. Using an assistant, remove the rear table and CAREFULLY set it aside.
REASSEMBLY
1. Using an assistant, CAREFULLY place the rear table in the approximate position and secure it with the two bolts. Do not tighten the bolts just make them snug.
2. Attach the two alignment jigs from the supplied tool kit to the two front table mounting holes. The bolt must go from the floor, up through the frame and then through the jig. Make sure the lip on each jig is facing down and resting on the edge of the cutter frame towards the operator side.
3. Have an assistant push the rear table firmly against the two alignment jigs and tighten the two bolts holding the rear table. Make sure there is no gaps between the jigs and the rear table.
7. Remove the adjusting bolt from the left underside of the cutting table.
8. Remove the two vertically oriented bolts holding the front table to the main frame.
9. Remove the two horizontally oriented bolts that hold the front table to the rear table.
4. Remove the two jigs.
5. CAREFULLY reinstall the front table reversing steps 1 through 10 of the DISASSEMBLY instructions.
6. Test for squareness.
660P Cutter
2 - 3
Page 10
SECTION 2 - MAINTENANCE & ADJUSTMENTS
CUTTING TABLE SQUARENESS
The cutting table must be properly aligned to the cutting line. If there is any misalignment adjust the table accordingly.
TESTING FOR CUTTING TABLE SQUARENESS
1. Check the cutting table alignment by any of the following methods: a) Check the cutting stick for a notch that has
been cut by the blade. If the notch is not parallel to the edge of the stick the table is not aligned properly.
b) Place a small block under the clamp. Lower
the clamp and knife using the blade change switch. Use a square to check the alignment of the blade to the sides of the cutting table.
Figure 1 - Cutting Table Bolts
Front View (front cover removed)
CUTTING TABLE ALIGNMENT
1. Determine what correction is necessary (see “Testing for Cutting Table squareness”).
2. Remove the front and rear covers (four Allen screws each).
3. Loosen, but do not remove, the two front table bolts and the left rear bolt (19mm) that secure the cutting table to the cutter frame, see
1 and 2
4. Loosen the lock nut on the table adjusting bolt. It is located underneath the table on the front left side.
5. Adjust the table adjusting bolt until the table is square.
6. Test for squareness. When satisfactory, lock the bolts from steps 2 and 3.
.
Figures
Figure 2 - Cutting Table Bolts
Rear View (rear cover removed)
660P Cutter
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Page 11
SECTION 2 - MAINTENANCE & ADJUSTMENTS
BACKGAUGE SQUARENESS
The backgauge must be parallel to the cutting line. If there is any misalignment adjust the backgauge accordingly. Test cutting table squareness before testing the backgauge.
A
A
TESTING FOR BACKGAUGE SQUARNESS
1. Cut several sheets of paper at the same time. Align them against the right side of the cutting area and evenly against the backgauge.
2. Remove and discard the pieces closest to the operator.
3. Turn the remaining sheets over and push them against the left side of the cutting area and against the backgauge.
4. Observe any excess trimmings from the cut. If there are any pieces left over, perform the backgauge alignment.
BACKGAUGE ALIGNMENT
1. Determine what correction is necessary (see “Testing for Backgauge Squareness”).
2. Remove the two screws A, see Figure 3.
3. Remove screw A and remove the backgauge drive cover, see Figure 4.
3. Loosen, but do not remove, the two bolts B on the left side of the backgauge, see Figure 3.
4. Loosen, but do not remove, the two nuts B on the right side of the backgauge, see Figure 5.
B
Figure 3 - Backgauge Drive Cover Rear Bolts
B
A
Figure 4 - Backgauge Drive Cover Rear Bolts
A
A
B
B
5. Adjust the two bolts as necessary to “square up’ the backgauge to the cutting line.
6. Test for squareness. When satisfactory, lock the bolts from steps 3 and 4.
7. Reinstall the backgauge drive cover.
CUTTING ACCURACY
See the Electrical Section for details on setting the “Rear Calibration Point.”
Figure 5 - Backgauge Adjusting Bolts
660P Cutter
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Page 12
Page 13
SECTION 3
TROUBLESHOOTING
IMPORTANT
THIS DEVICE MUST BE OPERATED WITHIN THE SPECIFIED AC LINE VOLTAGE. IF THE AC POWER FALLS OUTSIDE OF THE SPECIFIED LIMITS, A DEDICATED POWER LINE MUST BE USED. IF THE POWER STILL DOES NOT FALL WITHIN SPECIFIED GUIDELINES A POWER CONVERSION (BUCK/BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT IN POOR OR NO OPERATION.
Page 14
SECTION 3 - TROUBLESHOOTING
SYMPTOMS CAUSE CORRECTION
1. The cutter will not power on Power cord is not connected. Connect the power cord.
2. Main motor will not run. The overload protection device
3. The knife cannot be engaged. Have not started the main motor. Turn the main switch to the
4. Main motor clutch doesn't engage.
5. Knife down completely, but cannot return to top position.
F1 or F2 fuse is blown. Check and replace F1 or F2.
(OL) is activated. The knife timer control (T1 - cut
depth control) is defective.
The safety beam(s) are blocked. Clear any obstructions in the
Knife down push button(s) (PB-1 and PB-2) are defective.
The knife timer control (T1 - Cut depth control) is defective.
No oil pressure. Check or change the clutch.
Loud noise from the clutch area. Check and adjust the gap of
No clutch action. Check the bridge rectifier
Upper limit switch (LS-U) is defective.
Check the overload protection device (OL).
Check the knife timer control
Start position.
beam path. Check the knife down push button(s) (PB-1 and PB-2).
Check the knife timer control
clutch.
(RF). Check the upper limit switch
(LS-U).
The safety beam(s) are blocked. Clear any obstructions in the
Knife change switch (PB-K) is broken or in the wrong position
Knife down push buttons (PB-1, PB-2) are broken.
Knife adjustment timer (T1 - cut depth control) does not work.
Knife position is too low. Adjust knife height.
6. Clamp doesn't move. Oil pressure is too low. Perform hydraulic
beam path. Verify position and replace the knife change selector (PB-K) if necessary. Check the knife down push buttons (PB-1 and PB-2).
Change the new knife adjustment timer
adjustments.
IMPORTANT THIS DEVICE MUST BE OPERATED WITHIN THE SPECIFIED AC LINE VOLTAGE. IF THE AC POWER FALLS OUTSIDE OF THE SPECIFIED LIMITS, A DEDICATED POWER LINE MUST BE USED. IF THE POWER STILL DOES NOT FALL WITHIN SPECIFIED GUIDELINES A POWER CONVERSION (BUCK/ BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT IN POOR OR NO OPERATION.
660P Cutter
3 - 2
Page 15
SECTION 3 - TROUBLESHOOTING
6. Continued from previous page The same as the problem of knife
7. Clamp will not return to the up position
8. P ower co m es on bu t the backgauge drive motor does not run.
9. Main motor runs too slow and eventually the overload circuit shuts off the motor
10. Fuses F1 and/or F2 are blown. The main m otor centrifugal switch
11. The cutter beeps constantly
and the blade will not return to the top position.
12. During a cut the cutter beeps The knife is dull Sharpen the knife
cannot be engaged. Upper limit switch (LS-U) not
released. Oil pressure is too low. Perform hydraulic
The knife and clamp UP control (LS-U) does not work.
Poor connection to the backgauge drive m otor
The backgauge low speed, forward or backward relay is defective
The bridge rectifier (GF) is defective.
Fuses (F1 and F2) are blown. Check the fuses.
The centrifugal switch or starter capacitor are defective
or capacitor is defective.
The bridge rectifier GF is shorted Check the bridge rectifier
The bridge rectifier RF is shorted Check the bridge rectifier
The backgauge drive motor is locked.
The backgauge rear lim it switch is defective.
The cutter power was rem oved during a cutting cycle.
See corrective action above for knife cannot be engaged.
Check switch LS-U.
adjustm ents. Check the knife and clamp up control (LS-U).
Check the connection to the backgauge drive motor.
Check the backgauge low speed, forward or backward relay (R1, R2, and R 3).
Check the bridge rectifier (GF).
Check the centrifugal switch or starter capacitor (located under the end cover of the main m otor housing).
Check the centrifugal switch or capacitor inside m ain motor (located under the end cover of the main motor housing).
GF.
RF. Check that the backgauge table m oves freely.
Check the backgauge rear lim it switch (L S -S ).
Press either one of the yellow cutter buttons.
THIS DEVICE MUST BE OPERATED WITHIN THE SPECIFIED AC LINE VOLTAGE. IF THE AC POWER FALLS OUTSIDE OF THE SPECIFIED LIMITS, A DEDICATED POWER LINE MUST BE USED. IF THE POWER STILL DOES NOT FALL WITHIN SPECIFIED GUIDELINES A POWER CONVERSION (BUCK/ BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT IN POOR OR NO OPERATION.
The clamp pressure is to low. Perform the clamp pressure
Trying to cut too much paper. Reduce the amount of paper
adjustm ent.
being cut.
IMPORTANT
660P Cutter
3 - 3
Page 16
Page 17
SECTION 4
HYDRAULIC ADJUSTMENTS
Page 18
SECTION 4 - HYDRAULIC ADJUSTMENTS
18
PRESSURE
GAUGE 2
TAP 1
09
06
17
TAP 2
PERFORM THE FOLLOWING ADJUSTMENTS IN THE ORDER SPECIFIED
Please Note: You will need an assistant to push the yellow cutter buttons during these adjustments.
VALVE 17 - RELIEF VALVE
ADJUST PRESSURE READING GAUGE
VALVE 17
PURPOSE: This adjustment sets the maximum
95 +/- 5 kg/cm
pressure for the hydraulic system. It prevents motor overload.
PROCEDURE:
1. Supply hydraulic pressure to gauge 2 by opening tap 2.
2. Shut off the supply of hydraulic pressure to the pressure gauge on the front of the machine by closing tap 1. Note the gauge is not shown in the illustration above.
3. Turn on the 660 cutter.
4. Activate the knife and the clamp by having an assistant push both yellow cutting buttons simultaneously.
5. Loosen the lock nut on the relief valve 17.
6. While observing the reading on gauge 2, adjust valve 17 until the pressure indicated is 95 ± 5 kg/cm2.
7. Tighten the lock nut on valve 17.
8. Close tap 2 and open tap 1.
2
2
VALVE 06 - RELIEF VALVE
ADJUST PRESSURE READING GAUGE
+/-
30
VALVE 06
PURPOSE: Valve 06 adjusts the low pressure for
3 kg/cm
the foot pedal and the blade change mode.
PROCEDURE:
1. Supply hydraulic pressure to gauge 2 by opening tap 2.
2. Loosen the lock nut on the relief valve 06.
3. Have an assistant activate the clamp by pushing the foot pedal down.
4. While observing the reading on gauge 2, adjust valve 06 until the pressure indicated is 30 ± 3 kg/cm2.
5. Tighten the lock nut on the relief valve 06.
6. Close tap 2.
2
2
660P CUTTER
4 - 2
Page 19
VALVE 18 - SEQUENCING VALVE
SECTION 4 - HYDRAULIC ADJUSTMENTS
ADJUST PRESSURE READING GAUGE
+/-
1 kg/cm
VALVE 18 OPERATOR CLAMP CONTROL
60
50
+/-
10 kg/cm
PURPOSE: Valve 18 adjusts the clamp pressure.
PROCEDURE:
1. Loosen the lock ring and turn the outside clamp pressure control fully clockwise.
2. Activate the knife and the clamp by having an assistant push both yellow cutting buttons simultaneously.
3. Loosen the lock nut on valve 18.
4. While observing the reading on gauge 1, adjust valve 18 until the pressure indicated is 60 ± 1 kg/cm2.
5. Tighten the lock nut on valve 18.
6. While observing gauge 1, activate the clamp by pushing the foot pedal down.
7. Adjust the operator clamp pressure control to 50 ± 10 kg/cm
2.
8. Tighten the operator clamp pressure control lock ring.
2
2
1
OPERATOR
Operator
Pressure
Gauge
Lock Knob
Operator Clamp Pressure Adjust Knob
VALVE 09 - SEQUENCING VALVE
PURPOSE: Valve 09 adjusts the return timing
between the knife and the clamp. The clamp should return as soon as the knife reaches the home position.
PROCEDURE:
1. Loosen the lock nut on valve 09.
2. Activate the knife and the clamp by having an assistant push both yellow cutting buttons simultaneously.
3. Observe the return rate of the knife and clamp.
4. Adjust valve 09 according to the following guidelines:
the clamp moves first - the pressure is too high. If the clamp stays down - the pressure is too low.
5. Tighten the lock knob on valve 09.
Operator Clamp Control
660P CUTTER
4 - 3
Page 20
SECTION 4 - HYDRAULIC ADJUSTMENTS
660P CUTTER
Hydraulic Circuit Diagram
4 - 4
Page 21
SECTION 5
ELECTRICAL DESCRIPTION
&
ADJUSTMENTS
Page 22
SECTION 5 - ELECTRICAL & ELECTRICAL ADJUSTMENTS
START UP AND SHUT DOWN PROCEDURE
The paper cutter is designed to calibrate itself each time it is turned on (It also can automatically calibrate after a given number of cutting cycles - see item number 4).
Do not turn off the cutter’s power with the backgauge at the home position.
If the shut down procedure is not used cutting accuracy is not guaranteed.
SHUT DOWN PROCEDURE
ACTION RESULT
1. Press the The backgauge <FAST FWD> button will move towards the
operator
2. Release the The backgauge will
<FAST FWD> button stop moving. backgauge is at least 2 inches from the back of the cutting table
AUTOMATIC SHUT OFF
The paper cutter moves the backgauge to the rear point and shuts itself off after being idle for 10 minutes.
As outlined in the “START UP AND SHUT DOWN PROCEDURE,” it is necessary to move the backgauge forward and perform the power on calibration procedure.
Cutting accuracy is not guaranteed if the shut down/automatic calibration procedure is not used.
3. Turn the power off The cutter will shut
down.
660P CUTTER
5 - 2
Page 23
SECTION 5 - ELECTRICAL DESCRIPTION & ADJUSTMENTS
SETUP FOR PROGRAMMATIC MARK II
The 660P paper cutter is controlled by the Programmatic Mark II controller. Use the following procedure to make changes or verify settings in the Programmatic Mark II controller.
Note: the Programmatic Mark II controller is used in several different model paper cutters and therefore has an option (Option 8) that can be changed to accommodate models other than the 660P.
IMPORTANT KEYS AND THEIR FUNCTIONS
KEY FUNCTION
<PROG> Use to select the set up mode <0> thru <9> Use to change values <END> Used as an enter key <NEXT> Moves to the next field <LAST> Moves to the previous field Power OFF Memorizes a setting
5. Press <END> The first two options will be indicated at the bottom of the display. See Figure 1
6. Press the <NEXT> key to advance to the desired
option. Enter the desired value.
THE NEXT STEPS ARE VERY IMPORTANT. YOU MUST PERFORM THE FOLLOWING TO MAKE THE DESIRED CHANGES.
7. Advance through the menu, changing any
options as necessary, until the program number reaches PROG: 1.
8. Turn off the power.
Maximum cutting distance
Program Number
PROCEDURE
ACTION RESULT
1. Turn the power The backgauge will switch to the move all the way back. START position During this time the
display will indicate “BACK TO ORG
WAITING.....”
2. Press <PROG> The cursor will blink
indicating where to enter the choice for a program number
3. Enter the number The display changes to <0> for the option “PASSWORD X X X X” menu
4. Enter the password The display will indicate by pressing <1>,<2>, the digits as they are <3>, and <4> entered
C: 26” 496 PROG: 0
1: 674.9 mm 2: 050.0 mm
Option 1 Option 2
Figure 1 - Sample Display
660P Programmable Cutter
660P CUTTER
5 - 3
Page 24
SECTION 5 - ELECTRICAL & ELECTRICAL ADJUSTMENTS
f
h displ
ITEM
NUMBER FUNCTION
NORMAL SETTING NOTES
1 Rear calibration point 674.9mm* * Perform procedure for exact results
2 Backgauge pushout
3 Front safety size 050.0mm 020.0 mm with the false clamp installed.
4 Auto calibrate 0000~0099 Determines number of cutting cycles before
5 Distance before
6 Distance from the rear
7 Backgauge reverse
050.0mm Distance the backguage pushes the paper
distance
backgauge motor slows during cut size change.
calibration point before the backgauge break is applied
direction fine stop adjust
towards the operator after a cut.
automatic calibration occurs. Note: 0000 = Off
10mm If the distance is too short the cut accuracy may
be poor. If the distance is too long the size change will take longer.
000.1mm This value may be increased to 000.2mm if there is play between the worm gear and the backgauge.
1.4 This is the distance the backgauge moves in reverse before proceding slowly to the cut point. Note: A setting of 1.0 = 16mm.
8 Display Units 1111
660P CUTTER
This setting determines which model cutter AND the unit of measurement (inches or millimeters). 1111 for model 433 with display in inches 0011 for model 433 with display in millimeters 0000 for model 486 with display in millimeters 0001 for model 660 with display in millimeters 1100 for model 486 with display in inches
or model 660 wit
1111
Table 1 - Option Settings
5 - 4
ay in inches
Page 25
SECTION 5 - ELECTRICAL DESCRIPTION & ADJUSTMENTS
SETTING INSTRUCTIONS FOR ITEM 1 REAR CALIBRATION POINT
This procedure should be performed if there is an error in the cutting distance measurement.
This setting describes the distance from the cutting line to the furthest distance possible from the cutting line. It is referred to as the rear calibration point.
For reference purposes: Using a known size piece of paper, the piece of paper closest to the operator is the operator side piece and the piece of paper towards the rear of the machine is the non-operator side piece.
PROCEDURE
1. Write “op side” on the operator side of the sample paper and “non op side” on the non operator side of the sample paper.
2. Cut the sample paper in half.
For example: If the sample paper is 17 inches and it is cut lengthwise, the cutting distance must be set to 08.50 inches.
3. Carefully align the pieces together and determine the difference in
If the “op side” is longer you need to decrease the rear point value.
millimeters
, if any, in their lengths.
cording to the above guidelines.
6. Repeatedly push the <NEXT> key until “PROG:1” is displayed.
7. Turn the 660 cutter power off.
8. Wait 5 seconds and turn the power back on. Repeat this procedure until there is no difference in the lengths of the op side and non op side pieces of paper.
C: 26” 496 PROG: 0
1: 674.9 mm 2: 050.0 mm
Option 1 Add or subtract from this value
Figure 2 - Back Point Adjustment
If the “op side” is shorter you need to increase the rear point value.
4. Access the rear point adjustment (by default the first item is rear calibration point). See detailed instructions in this section.
5. Divide the distance measured in step 3 in half. Increase or decrease the value of option 1 ac-
660P CUTTER
5 - 5
Page 26
SECTION 5 - ELECTRICAL & ELECTRICAL ADJUSTMENTS
TERMINAL LED NAME PORT DESCRIPTION STATUS
3 400 KEY Input Key switch NO 12 401 PB-1 Input Cut pushbutton 1 NO 13 402 PB-2 Input Cut pushbutton 2 NO 14 403 LS-D Input Knife down limit switch NO 15 404 LS-U Input Clamp top limit switch NC 16 405 LS-A Input Photoelectric protection circuit NC 17 406 T1 Input Knife adjustment timer NO 18 407 PB-K Input Knife change switch NC 20 410 LS-C Input Foot pedal switch NO 23 411 NC-1 Input Mark-II control NC 25 412 LS-E Input Backgauge rear safety switch NC 25 413 LS-E Input Backgauge rear safety switch NC 6 430 D Output Knife down relay N/A U 431 U Output Knife up relay N/A 9 432 T1 Output Knife adjustment timer N/A P 433 P Output Clutch N/A 19 434 BZ Output Buzzer N/A 4 435 M Output Main motor control N/A C 436 C Output Clamp pressure relay for foot N/A 27 & 2A 437 TR1 Output Transformer for Mark-II N/A
Table 2 - PLC Inputs and Outputs
660P CUTTER
5 - 6
Page 27
SECTION 5 - ELECTRICAL DESCRIPTION & ADJUSTMENTS
KEY
ABBREVIATION DESCRIPTION
O.L. Main motor thermal overload relay Key Main key switch PB-1 Cut push button 1 PB-2 Cut push button 2 PB-K Knife change switch LS-D Knife bottom position switch LS-U Clamp pressure top position switch LS-C Foot pedal switch LS-E Backgauge rear safety switch NC-1 Signal from MKII control A Photo electric control (optional) D Knife down relay U Knife up relay C Clamp pressure relay for the foot pedal M Main motor control T1 Knife adjustment timer ML Motor pilot light CL Cutting line light TR Main transformer RF Clutch rectifier circuit BZ Buzzer P Main motor clutch
Table 3 - Main Electrical Diagram Key
660P CUTTER
5 - 7
Page 28
SECTION 5 - ELECTRICAL & ELECTRICAL ADJUSTMENTS
660P CUTTER
Figure 3a - Electrical Diagram for PLC
5 - 8
Page 29
SECTION 5 - ELECTRICAL DESCRIPTION & ADJUSTMENTS
KEY
ABBREVIATION DESCRIPTION
LS-D Knife bottom position switch
LS-R Micro adjustment switch
LS-S Rear point switch
P1 Backgauge brake
R1 Backgauge on/off relay
R2 Backgauge forward/reverse relay
R3 Backgauge fast/slow relay
SB Backgauge slow speed adjustment
SSR Slow start relay
TR1 MKII power transformer
Figure 3b - Electrical Diagram for Programmatic MKII and Backgauge Motor Circuit
660P CUTTER
5 - 9
Page 30
Page 31
APENDIX A
600P Cutter Quality Control Check List
Page 32
Page 33
Duplo USA Corporation
Quality Control Check List
660 Cutter
Serial Number: _______________________________________ Date: _________________ Technician Name: _____________________________________ Dealer: ________________ Company: ___________________________________________ Phone: ________________ Address:_____________________________________________ City:__________________ State: _____________________ Zip:_____________________ Fax: __________________
Tech
OK
Operator sign off / acknowledgement:______________________________________________
Quality control performed by: ____________________________________________________
___________________________________________________________________________
___________________________________________________________________________ ___________________________________________________________________________
Check Point Comments:
1. Check record AC Power VAC. Check control panel by
2.
pressing the buttons.
3. Check back gauge clutch by
pushing the adjustment knob in the front of the machine.
4. Input a size and press run to
see if C# and 1# matches.
5. Testing balance for the square
ness of the back gauge.
6. Check the vertical square ness
of back table.
7. Check from panel pressure
gauge for 50 to 60 PSI during a cut.
8. Check the maximum cutting
ability.
9. Program and perform a 10” and
a 5” cut.
10. Check foot pedal operation.
11. Check knife cutting line light
is on.
12. Perform a overall visual
inspection for appearance.
13. Check and write down
program 0” parameters on the right side of this sheet.
Comments
1)
2)
3)
4)
5)
6)
7)
8)
Page 34
Page 35
Installation Check List
1) Check voltage on the machine after electrical wiring is done by checking the T and L on the terminal board to see if it is between 208v -232v, if not you will have to install a buck booster transformer
Turn on the machine and check the control panel by pressing of any of the buttons and to see
2) if the LED display is ok
3) Check the clutch by pushing the fine adjustment knob on the front of the machine, by pushing it in and out this is to check to see if the gap on the clutch sounds right if not please refer to the instructions later in this manual.
4)
Input a size into the control panel press the run button verify if the # C and # I matches,, if so then you do not have to do a thing . If it does not match, then you have to adjust the low speed adjuster in the main electrical panel on the bottom of the box (white knob) by turning the knob very slightly at a time and by pressing the run button till the sizes matches the control panel
5) Put a stack of paper on the right side of the cutter and select a size, then press run, make a cut, now move the stack to the left side of the cutter make a cut, if there are any shavings, you will have to adjust the backgauge till you have no more shavings and the backgauge is square. Please refer to the maintenance manual on page 2.5 to show you how to do this adjustment.
Put a full stack of paper into the cutter, make a cut then check it by taking a sheet form the top
6) and one from bottom and comparing them to see if the paper is cut at a angle. If it is at an angle you must make an adjustment, instructions are in the later part of this manual.
7) Put a 10" cut into 1# place, then press next, then put a 5" cut into 2# then press next then press end twice then press the auto button and the machine will go to the first cut, cut some paper for the 10" cut, then cut the 5" cut and put them together to see if they match, if not, you must adjust the rear calibration point till it matches both cuts. Instructions are on page 5.5 of the maintenance manual
8)
This is to check for the maximum cutting ability, Place a full stack of heavy paper stock into the machine and make a cut, if it cut all the way thought then it’s OK, if not, go to the later part of this manual for more information.
9) Check the pressure gauge on the front of the machine by making a cut. It should be about 50 to 60 p.s.i.
10) Check the foot pedal to see if the clamp comes down and is operational.
11) Check and see if the knife cutting line light is on if not replace it. Instruction are in the latter part of this manual.
Page 36
12) Check knife changing switch by turning the switch to the #1 position and pressing the two
yellow button the knife will go down and stay down then turn the switch to #0 and the knife will go back up if so it is ok, if not go to the maintenance manual on page 4.3, valve adjustment #9
Write the program parameters down on paper by pressing program then #0 then pressing the
13) # 1,2,3,4, buttons, then press end Then go thought # 1 -
8 and by pressing next Jill you get to the
end of the parameters press the next or last twice then press reset to return to the main program
Now install the two side tables on the machine The instruction are on page 9 & 10.
14)
15) Perform a visual inspection (cover and overall appearance) if all looks good, you may sign off on the installation / Q.C. form
Page 37
How To Adjust The Full Maximum Paper Cutting Ability
Take a full stack of heavy paper stock and place it into the cutter and make a cut, if it cuts all the way thought then you are ok, but if does not cut all the way thought then you have to do the following:
1) Take the top back cover off
Adjust the clamp pressure top position switch, by loosening the allen screw on the long arm
2) of the switch and moving it more down towards the clamp and do this a little at a time
3) Make a cut every time you adjust the long arm do this till you can cut all the way thought the stock
Page 38
How To Adjust The Backgauge Clutch
1) Make sure the power is off to the machine.
2)
Take off the long side cover one bolt is under the cover and the other two are on the side of the fence.
3) Loosen the two nuts on the clutch and loosen the three allen screws.
4)
Open the gap on the clutch and place two sheet of 20 lbs. stock one on the top and one on the bottom.
5) Ad just the gap so that the paper is just touches the gap between the two plates.
6) Tighten the allen screws and the two nuts.
To check if the gap is right, tam on the power to the machine and push in and out the fine adjustment knob on the front of the machine to hear if there is a clicking sound that is the clutch engaging and disengaging if it sound right you are done.
Page 39
Cutting Table Vertical Adjustment
1) Take a full stack of paper and put it into the machine and make a cut, compare the top sheet with the bottom sheet to see if it is at a angle or if it matches if not go to the next step.
2)
Take off the front and bottom back cover.
3) Loosen but do not remove these bolts there are 2 of them that are horizontal bolts in the front, the other 2 of them are vertical in the back of the machine, these 4 bolts are 19mm.
4)
There are 2 smaller vertical bolts under the back of the cutting table, on the left and the right side These are the ones that change the angle of the cutting table loosen the 2 nuts on the bolts so you can adjust the bolts.
5) By determining the angle needed to be adjusted by the cut sheet that you have done, lower or raise the bolts evenly on both sides, by making a cut and adjusting the bolts, till it is vertically square.
6) Tight all the nuts and bolts and make another cut of a full stack of paper to confirm the adjustment has not moved. If there is no change, you are finished. If so you have to re-start from
until it is square.
1)
Page 40
How To Replace The Knife Cutting Line Light
1) Take top front cover off
Loosen the bolt and pull the light away from the mounting bracket
2)
3) Disconnect the male from the female connector and remove the 2 phillip screws from the mounting bracket and take out the old light
4) Put the new light in by connecting the male to the female connector and putting the 2 phillip's screw back into the mounting bracket
5) Put the mounting bracket bolt back on the bar with the bracket and tighten the bolt
6) Alien the light so it is between the knife blade and the clamp so that the line can be seen on the cutting stick
Page 41
Model 660 Trouble Shooting Guide
(Controlling Switches)
Code Symptom Cause
Please check top switch 1) Machine will not let you cut. Ls-u clamp and machine is buzzing 2) Bad continuity on switch. pressure top all the time. 3) Check switch wiring. switch is bad.
Encoder error 1) In a program and making a Encoder is bad. Please check encoder. cut and error comes up.
2) Press run button and error comes up.
Page 42
660 is costantly buzzing
This occurs when the machine
1. Change the Knife
changed. Turn the knife change switch
Symtom Cause
660 is constantly buzzing
has done 3000 cycle and it is prompting a knife change
Correction
2. If the knife has recently been
form left to right.Depress both yellow cut button ,the knife will come down to the bottom position.Turn the knife change switch form right to left, the knife will return to the top position
Page 43
Model 660 Trouble Shooting Guide
(Mark-II Programmatic Control)
Symptom
(a) Mark-II can not start
(b) Mark-II starts
completely but can not operate.
(c) Backgauge moves
in high speed, but low speed can’t be engage.
(d) Encoder problems.
(e) Backgauge motor
Control is broken.
(f) Power is ON, cutting
light glows, but can’t start the motor.
(g) When starting the
motor, the run indicator light glows, but motor can’t run.
Possible Cause / Correction
1. The clamp doesn’t to top position ,LS-E doesn’t work (wires SS,UL )
2. The backgauge rear safety switch (LS-E) is broken (wires M, 25 )
3. The fuse is blown ( fuse 3 )
4. Mark –II programmatic control is out of order
1. Backgauge locking handle does not reset (wire SS ,RL )
2. The clamp doesn’t return to top position , Mark-II can not run (wires SS, RL).
1. Backgauge low speed adjuster is broken (SB)
1. Cut position is incorrect.
2. After calibration the rear position ,backgauge move forward in high speed, then locked.
3. Backgauge moves forward a section in high speed , then locked
4. Sunray 2 error will come on
5. If encoder is bad ,if you have more than 1’’ on your cut size ,check the encoder.
1. When R1,R2 & R3 are activated, sparks are shooting out of the contacts, or the contacts are melted, the SSR relay is broken, replace the SSR so it will kill the sparking on the contacts.
1. Key switch is broken (wires M,3)
2. PLC has no power, PLC doesn’ t work
1. The motor thermal overload is overloaded (OL)
Page 44
Symptom
Possible Cause / Correction
(h) Clutch problem
1. Large noise : the gap of clutch is too small Correction : readjust the gap
2.The power to the clutch is not enough The gap on the clutch is too big The voltage is to low Correction : is to install in series a Condenser (220uf ,50v) on both sides of the terminal (wires +,- )
(i) Knife is coming
down too slow.
1. Lubrication oil is not enough
2.Clutch is out of order
3.Hydraulic pressure problems
(j) Control panel shows:
Back to Org.
Wait…
1)
Backgauge moving to slowly so you are unable to input any
numbers in to the control panel.
2) Adjust the slow speed pot adjustment in the main electrical panel on the inside of the machine, on the bottom (white knob) to speed up the backgauge and, so that the display matches the C# and the 1# correctly.
Page 45
T1.Knife adjustment
1. The knife cannot be engaged ( go down )
Bad contacts on D& 8
Codes
Ls-U . clamp pressure
top position switch
Ls-D. Knife bottom
position switch
1. When depressing PB-1& PB-2 cut button
2. If a deep cut is made ,buzzer will beep until both
Symptom
1. When after making a cut ,the knife goes up, buzzer beeps for one second ,then stop
P.s. The same as the problem as cutting a large pile of sheet
2. Turn on the power ,buzzer beeps ,then you start the motor buzzer beeps once ,but you can’t make any cuts ,and the Mark-ll programmatic will not run
,buzzer beeps, but machine doesn’t make a
any cuts
cut button are released , then knife goes up to the top and the motor will shut off automatically.
Trouble Shooting Guide
Model 660
( Controlling Switches )
Cause
Ls-u does not work
Ls-u has no action
Ls-D doesn’t reset
Ls-D doesn’t work ,or
knife changing switch
is wrong
timer
Pb-K. Knife change
Ls-C Foot pedal
Nc1. From Mark-ll
2. When making a deep cut ,buzzer will beep until both cut button are released ,then knife goes up to the top and the motor
will shut off automatically
1.The knife comes down and stop at the bottom will not return to the top position
,but
1. Turn on the power,but you can not start the motor ,buzzer will beep for 3 seconds and then stop . At this time , the foot pedal is not function automatically ,then you can start the motor
1. The knife can not make a cut
2.When knife comes down and occasionally holds back ,and you need to re-press both cut buttons
T1 has no action
Bad contacts M& 18
Bad contacts 2&21
Ls-C is locked
Bad contacts M&23
Page 46
Model 660p
Ls-U upper limit switch
Switch position N/o O –3 4- O N/o
Wiring mark UL SS
Ls-D lower limit switch
N
o connection 6 8 M 20 no connection
T1 . Knife adjustment timer Pb-K Knife change switch NC1. From Mark-ll
wirers M & 17 wires M & 18 wires M & 23
N/c N/o Common Common N/o N/c
O O O O O O
D & 8 2 & 21
Machine wiring for switches and the timer
__________________________________
N/c O-1 2- O N/c
M 15
N/o O-3 4-O N/o
14 M
__________________________________
N/c O-1 2- O N/c
SS DL
Backgauge limit switch
Common N/o N/c
25 no connection M long arm switch
__________________________________
Common N/o N/c
SS no connection SL short arm switch
Foot peddle switch
Left switch Right switch
Page 47
Model 660P
Trouble Shooting Guide
Sympton Possible Cause Correction
Knife or clamp will not 1) Bad Ls-u top clamp switch Replace the
go down when foot or Ls-d down switch switch pedal is pressed or ( check note ) when the two yellow
button is pressed 2) T1 is not working right Replace T1
Note : This is how to check the top Ls-u and bottom Ls-d switches to see if
they are ok
1) Remove back top cover and find the switch Ls-u ,next take the allen screw off one side of the Ls-u switch and tilt it to the side
2) Remove the side cover where the Ls-d switch ,so you may touch the switch when you have to
3) Now have someone hold the arm of the Ls-u switch in the up position
4) Turn on the power to the machine
5) Now press the two yellow buttons and release the arm of the Ls-u switch ,then touch the Ls-d arm ,next then move the arm of the Ls-u into the up position
6) Turn off the power to the machine and put all the parts back in there place
Comment : If the U relay works on hydraulics system then the switches are
are working right ,also you can check the inputs and outputs
signal on your PLC unit
3) The knife down and up Replace relay is not working relay in the down mode on the hydraulics
#8
Page 48
Explanation : This is a three pin output connector ,when the switch is
The T1 timer is a eight pin potentiometer to witch has two sides to it and
-----------------------------------------------------------------------------------------
Wiring for the 660P
T1 Knife adjustment timer
has two pins for the power
power inputs
• o 2 7
---------------------------------------------------------------------
Right side of switch
n/c n/c 5 8
n/o n/o
6 8
---------------------------------------------------------------------
Left side of switch
n
/c n/c 1 4
n/o n/o
-----------------------------------------------------------------------------------------
activity the switch goes for normally close to normally open
1 3
Page 49
Wiring for the new switch on the top of the knife
Knife top position Clamp top position
|______________| N/c |____________________| N/c |_____________ | | | | | | |
S S A A U L
The SS,AA,and UL are all wiring points to the terminal, and on the switch.
Explanation: New switch on the top of the Knife. The knife top position switch is a series connection with the clamp top position switch, it is a new safety device for the Mark- II Programmatic signal, when the knife does not go up to the top position, because of it, the backgauge will not move to the next size.
switch switch
Page 50
NOTE:
New Light Safety Curtain for 660 Cutter
The new light safety curtain will not work the older machines, because they do not have a AC 24 V power wire fitted, if you would like to mount the new light safety curtain on the older machines you need to connect a 24 V wire form the transformer, and also you would have to do some modifation to the side tables, in order to mount the light safety curtain.
The light safety curtain will work on machine above the serial number 0104034, and will not work below
that serial number without doing modifation.
Important Note: Use discretion when ordering this and any other parts or options. Check the serial number of the machine or machines and compare them to the implementation number before ordering this option.
Fax all parts orders to the Parts Department at (949) 752-7766. If you require further information or assistance, contact Duplo U.S.A. Technical Department, Graphic Arts Division at (949) 752-8222.
Page 51
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