Horizon APC-61 User Manual
A
PC-61 Revision Control List
x
1-9,1-10,1-11,2
Manual No. Date Bulletin Code S/N applied History
US504004-00 Jan/17/2001 (First Edition)
1.Correcting the description of "2-11 Hydraulic Pressure Does not Operate." 2-20
2.Correcting the Hydraulic Circuit to (For S/N 100001 to 122899) and (For S/N
123001 or above). 5-3.4
US504004-01 Jun/4/2001 1.Adding precautions on P.C.board and ROM IV
2.Adding the relay in the control bo
3.Correcting producers No. for the rlay 7-8
4.Correcting wiring diagrams 7-6, 7-10, 7-11
US504004-03 Feb/27/2008 1. Adding the 61II-related pages.
2. Correcting the term "cut knife" to the "cutting knife".
3. Correcting the term "back gauge" to the "backgauge".
Page
6-4
23,2-24,2-25,226,2-27,2-28,316,3-17,6-5,6-6,67,6-8,6-9,7-14,715,7-16,7-17,718,7-19
All Page
All Page
FOREWORD
Paper Cutter
Model APC-61
Important Information
This service manual is designed to help you to repair and maintain the APC-61 in order to keep it in good operating condition.
Please read and understand the instructions in this service manual before performing any repair or maintenance.
- Horizon International Inc. shall not be liable for incidental or consequential damages resulting from: improper or inadequate
maintenance by the customer; unauthorized modification or misuse; or operation outside of the environmental specifications
for the product.
- Horizon International Inc. follows a policy of continuing improvement in design and performance of the product. Therefore,
the product design and specifications are subject to change without prior notice and without our legal obligation.
- All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without the
prior written consent of Horizon International Inc.
US504004-03080131/APC61/03E/KY/NT/P6/I9/P7
1
Safety Precautions
- Please read and understand all safety instructions which include the terms WARNING, and CAUTION. If these safety instruc-
tions are ignored, personal injury may result.
- The repair, maintenance and safety instructions in this manual are valid only when the repair or maintenance work is performed
according to the procedures described in this manual.
- The term WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
- The term CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It may
also be used to alert against unsafe practices.
- Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in this
manual and the warning labels on the machine are therefore not all-inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation, repair
or maintenance could cause injury to personnel. Do not attempt to operate any switch, valve, or any electrical device when it has
been locked or tagged out.
- Some of the drawings in this manual show the machine uncovered for explanations of the details inside the machine.
2
I. Necessary Tools for Maintenance and Repair
9
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.C
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.
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otal Counts Setting
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umeric
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umbers
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Use the following tools for maintenance and repair.
1. Screw Driver No. 2
2. Screw Driver 6 to 7 mm
3. Allen Wrenches 1.5, 2, 2.5, 3, 4, 5, and 6 mm
4. Open-ended Wrench 5.5 x 7, 8 x 10, 13 x 17 mm
5. Box Wrench 5.5 mm
6. Snap-ring Expander
II. Abbreviations in This Manual
2. The following abbreviation represent electronic and electrical parts.
Abbreviation
Meaning
CL Clutch
BK Brake
SW Switch
PS Proximity Switch
mSW Micro-switch
M Motor
1. The following abbreviations represent wire colors.
Abbreviation
Color
Abbreviations
Color
BRN Brown PNK Pink
RED Red LBL Light Blue
ORN Orange YEG Yellow Green
YEL Yellow YEO Yellow Orange
GRN Green LYE Light Yellow
BLU Blue GND Ground
VIO Violet
GRY Gray
WHT White
BLK Black
LED Light Emitting Diode
VR Potentiometer
RY Relay
AS Assembly
1-5 Entering Service Scree
"Numeric
"Normal Cutting" Scree
"Maintenance" Scree
"ormation" Scree
pad" Scree
se
our digits
utton is pressed,the
1-
.
"Service" Scree
Moter Home Position Displ
R
r to 1-7
iz
OK]
.
means
a page that is
related to
APC-61II.
will
3
Contents
FOREWORD........................................................................... 1
Paper Cutter ............................................................................ 1
Model APC-61 ......................................................................... 1
Important Information ........................................................... 1
I. Necessary Tools for Maintenance and Repair .................. 3
II. Abbreviations in This Manual .......................................... 3
1. Machine Parts Descriptions
1-1 General View ..................................................................... 1-2
1-2 Operation Panel Descriptions (T61)................................ 1-5
1-3 Operation Panel Descriptions (M61) .............................. 1-7
1-4 Cover Descriptions............................................................ 1-8
1-5 Entering Service Screen (61II)......................................... 1-9
1-6 Calibration of Home position (61II)................................ 1-10
1-7 Checking Motor Home Position Distance (61II)............ 1-11
2. Troubleshooting
2-1 blinks on the Display (Backgauge Does Not Operate)
Part 1 ................................................................................. 2-2
Part 2 ................................................................................. 2-3
Part 3 ................................................................................. 2-4
Part 4 ................................................................................. 2-5
2-2 Cut Size is Not Equal
Part 1 ................................................................................. 2-6
Part 2 ................................................................................. 2-7
2-3 Knife Does Not Lower (Clamp Does Not Lower Either)
Part 1 ................................................................................. 2-8
Part 2 ................................................................................. 2-9
Part 3 ................................................................................. 2-10
2-4 Knife Does Not Lift
Part 1 ................................................................................. 2-11
Part 2 ................................................................................. 2-12
2-5 Clamp Lowers but Knife Does Not Lower ..................... 2-13
2-6 Clamp Does Not Lower Though Foot Pedal
Is Stepped On................... 2-14
2-7 Backgauge Does Not Operate
Part 1 ................................................................................. 2-15
Part 2 ................................................................................. 2-16
2-8 Backgauge Does Not come Forward
(But goes backward) .......... 2-17
2-9 Backgauge Operates By Itself.......................................... 2-18
2-10 Nothing Is Shown on Displays ....................................... 2-19
2-11 Hydraulic Pressure Does Not Operate.......................... 2-20
2-12 Knife Is Down before Operation ................................... 2-21
2-13 Knife Lower Limit Position Varies ............................... 2-22
2-14 Backgauge Does Not Move (61II) ................................. 2-23
2-15 Error Code (61II)............................................................ 2-24
4
3.Adjustment
3-1 Fine Adjustment of Cut Size
(Different is about 0.1 mm) ................. 3-2
3-2 Adjustment of Cut Size
(Different is about between 0.1 and 0.2 mm)................. 3-3
3-3 Rough Adjustment of Cut Size
(Different is about 0.5 mm) ................. 3-4
3-4 Adjustment of Electromagnetic Brake Gap................... 3-5
3-5 Adjustment of Electromagnetic Clutch Gap .................. 3-6
3-6 Adjustment of Knife Replacement Position ................... 3-7
3-7 Adjustment of Knife Lower Limit Position.................... 3-8
3-8 Adjustment of Cutting Line Width ................................. 3-9
3-9 Release of Locked Knife................................................... 3-10
3-10 Pressure Adjustment of Hydraulic Pump .................... 3-12
3-11 Right Angle Adjustment of Backgauge to the Table....... 3-13
3-12 Horizontal Adjustment of Backgauge to the Table ..... 3-14
3-13 Parallel Adjustment of Backgauge to the Knife .......... 3-15
3-14 Backgauge Drive Section Mechanism (61II) ............... 3-16
3-15 Spindle Section Mechanism (61II)................................ 3-17
4.Repair
4-1 Replacing Knife Holder.................................................... 4-2
4-2 Replacing Clamp............................................................... 4-5
4-3 Replacing Backgauge........................................................ 4-8
4-4 Replacing Backgauge Block............................................. 4-9
4-5 Replacing Knife Link A and B......................................... 4-10
4-6 Replacing Clamp Link A and B....................................... 4-11
4-7 Replacing Joint (For Clamp) ........................................... 4-13
4-8 Replacing Joint (For Knife) ............................................. 4-14
4-9 Replacing Rod End ........................................................... 4-16
4-10 Replacing Rod ................................................................. 4-17
4-11 Replacing Encoder .......................................................... 4-18
4-12 Replacing Electromagnetic Brake................................. 4-19
4-13 Replacing Electromagnetic Clutch................................ 4-20
4-14 Replacing Belt (For High Speed)................................... 4-21
4-15 Replacing Belt (For Low Speed).................................... 4-22
4-16 Replacing Motor (For High Speed)............................... 4-23
4-17 Replacing VC Relay and Contactor .............................. 4-24
4-18 Replacing Sensors (Detecting Knife Replacement
Position, Knife Lower Limit Position) ..... 4-25
4-19 Replacing Power Supply ................................................ 4-26
4-20 Replacing Operation Panel ............................................ 4-27
4-21 Replacing Control Board ............................................... 4-28
4-22 Replacing Fuse and Resetting Thermal Relay ............. 4-29
4-23 Replacing Limit Switches............................................... 4-30
4-24 Replacing Knife Holder Upper Limit Position Sensor 4-31
4-25 Replacing Limit Switch
for Clamp Upper Limit Position.................. 4-32
4-26 Replacing Cutting Line Bulb ......................................... 4-33
4-27 Replacing Electromagnetic Valve.................................. 4-34
5
5.Hydraulic Parts
5-1 Hydraulic Parts Description
(For S/N 100001 or above) ............................................... 5-2
5-2 Hydraulic Circuit .............................................................. 5-3
(For S/N 100001 to 122899) .............................................. 5-3
(For S/N 123001 or above) ................................................ 5-4
5-3 Hydraulic Parts Descriptions
(For S/N 099999 or below) ................................................ 5-5
5-4 Hydraulic Circuit (For S/N No.099999 or below) .......... 5-6
6. Electrical Parts Description
6-1 Identification and Location of Motors and Encoder ..... 6-2
6-2 Identification and Location of Sensors and Switches .... 6-3
6-3 Identification and Location
of Components in the Control Box .... 6-4
6-4 Location and Name of Pairs in Control Box(61II) ........ 6-5
6-5 Panel Internal Layout and Name (61II) ......................... 6-6
6-6
Hydraulic Pressure and Motor Unit Layout and Name (61II) ..
6-7 Backgauge Motor Section Layout and Name (61II) ...... 6-8
6-8 Parameter Settings of Amplifier
for Servo Motor (61II) ........................ 6-9
6-7
7-4 Control Board (QPW-153D), LED and Main Parts ...... 7-5
7-5 Control Board (QPW-153D) Connector Layout ............ 7-6
7-6 Foot Switch Control Board (QPW-155A) ...................... 7-7
7-7 Foot Switch Control Board (QPW-155A) ...................... 7-8
7-8 Control Box Schematic Diagram ..................................... 7-9
7-9 Wiring Diagram ................................................................ 7-10
7-10 Terminal-1 ....................................................................... 7-11
7-11 Terminal-2 Wiring Diagram (Inside of Control Box) . 7-12
7-12
LED and DSW of Control P.C.B. P083411(QPM-195) (61II) ....
7-13
LED and DSW of Panel P.C.B. P071811(QPM-157) (61II)..
7-14 P083411(QPM-195) Connector Connection (61II) ...... 7-16
7-15 New Circuit (Power System) (61II) ............................... 7-18
7-16 Safety Circuit Performance (61II) ................................ 7-19
7-14
7-15
7. System Wiring and Connections
7-1 Board Connections ............................................................ 7-2
7-2 CPU Board (QPW-162) .................................................... 7-3
7-3 Display Board M61:QPW-175, T61:QPW-176 .............. 7-4
6
1.Machine Parts Descriptions
1-1 Machine Parts Descriptions ........................................................................... 1-2
1-2 Operation Panel Descriptions (T61) ..............................................................1-5
1-3 Operation Panel Descriptions (M61) .............................................................1-7
1-4 Cover Descriptions ..........................................................................................1-8
1-5 Entering Service Screen (61II) .......................................................................1-9
1-6 Calibration of Home Position (61II) ............................................................1-10
1-7 Checking Motor Home Position Distance (61II) ........................................ 1-11
1-1
APC-T61
HYDRULIC CUTTER
1-1 General View
Clamp
This clamp holds sheets not to move the sheets
when they are cut.
(500 to 1,700kg/cm )
Knife Angle Adjust Lever Fix Screw
Knife angle adjust lever is fixed with this screw.
Knife Angle Adjust Lever
2
The knife angle adjusted with this lever.
Cutting Knife
Cutting Depth Adjust Dial
This dial is used to adjust the knife lower limit
position only when Knife Operation Mode
Select Switch is turned off.
Cutting Knife ON/OFF Switch and Lamp
?
?
APC-T61
HYDRULIC CUTTER
7 8 9
4 5 6
1 2 3
-
P
+
P
.
E
c
0
-
S
+
S
When this switch is turned up, only clamping
will be performed with lamp lighting.
Power Switch
The type of this switch is the breaker.
Backgauge Adjust Knob
This knob is used to adjust backgauge.
Paper Clamp Pressure Indicator
Paper Clamp Pressure Adjusting Knob
Foot Pedal
This pedal is used to lower clamp.
Oil Tank
It can contain 40 liter of oil.
1-2
1-1 General View
Pressure Support Plate
Control Box
Light Switch
When turning up the lever, the table is
lightened up, but it becomes difficult to
see the cut line.
Backgauge
This backgauge is the back stop of
sheets to be cut.
Back Table
Side Guides
These guides are register plates for
preparing the sheets right angle
against cutting knife.
Oil Gauge
1-3
APC-T61
HYDRULIC CUTTER
1-1 General View
Cutting Button A
Key Switch
Photoelectric Guard
When there is a foreign object
on the optical line between
?
?
APC-T61
HYDRULIC CUTTER
7 8 9
4 5 6
1 2 3
-
P
+
P
.
E
c
0
-
S
+
S
photoelectric guards, the ray is
blocked and safety function
operates. Therefore, knife and
clamp does not lower.
Oil Feed Cover For Backgauge
Backgauge Cover
Cutting Button B
This button and cutter A
button must be pressed
simultaneously to start
to cutting operation.
1-4
Motor encoder Section
The high speed motor, low speed motor,
electromagnetic clutch, brake and encoder are housed.
1-2 Operation Panel Descriptions (T61)
APC-T61
HYDRULIC CUTTER
Full Memory Lamp
This lamp lights when input memory is full.
Push-out Memory Lamp
Repeat/Setup Lamp
Power Lamp
HYDRULIC CUTTER
Key Switch
Hydraulic Pressure Lamp
Hydraulic Pressure ON/OFF Switch
High Speed Backward Button
This button is used to move backgauge
backward at high speed.
Low Speed Forward Button
This button is used to move backgauge
forward at low speed.
High Speed Forward Button
This button is used to move backgauge forward at
high speed.
Repeat/Setup Select Button
In normal operation, this switch must be set to the repeat
mode. (The above repeat lamp lights up.) The size memory
button must be set to the setup mode.(The above setup Lamp
lights up.)
Repeat
Current position
Setup
Put-out
Memory
Presetting
P
S
Program
P+-
S+-
Setup
No More
Memory Opar Error
?
Program No.
Delete
Memory Button (for the Current Position)
Step Delete Button
Step Backward Button
Step Forward Button
Operation Error Lamp
?
Step.No.
Memory
Push-out
789
456
123
.
0
E
c
Replacing
knife
ON
Memory Button (for the Keypad Input)
Knife Operation Mode Select Switch
This switch is used select knife operation
mode, cutting mode or knife replace
mode. In normal operation, this switch
must be set to the cutting mode.
Push-out Memory Button
1-5
APC-T61
HYDRULIC CUTTER
1-2 Operation Panel Descriptions (T61)
Step Number Display
Program Number Display
Presetting Size Display
Current Position Display
This display shows the backgauge
current position.
Repeat
Current position
HYDRULIC CUTTER
Program Forward Button
Program Backward Button
Program Delete Button
Decimal Point/Clear Key
The decimal point is input in the first press and
the number is deleted for the delete key in the
second press.
Numeric Keypad
Setup
Put-out
Memory
Presetting
P
S
Program
P+-
S+-
Setup
No More
Memory Opar Error
?
Program No.
Delete
Step.No.
Memory
?
Push-out
789
456
123
.
0
E
c
Replacing
knife
ON
Enter Key
When this key pressed after inputting the number,
the backgauge moves to the set position.
1-6
APC-M61
HYDRULIC CUTTER
1-3 Operation Panel Descriptions (M61)
Program Number Display
Step Number Display
Current Position Display
This display shows the backgauge
current position.
Hydraulic Pressure Lamp
Power Lamp
Key Switch
Hydraulic Pressure ON Button
Hydraulic Pressure OFF Button
High Speed Backward Button
This button is used to move
backgauge backward at high
speed.
Low Speed Forward Button
This button is used to move backgauge
forward at low speed.
High Speed Forward Button
This button is used to move backgauge
forward at high speed.
Presetting Size Display
Current Position Display
Power
Hydraulic
Backgauge Travel
Memory
Program No. Step No.
Presetting
Step
1 2 3 4 5 6
Memory Delete
Repeat / Setup
Step Forward Button
Size Memory Button
Push-out Memory Button
Knife Operation Mode Select Switch
This switch is used to replace knife.
In normal operation, this switch must be set
Step Forward
Size
Memory
Push-out
Memory
Program
Forward
Replacing Knife
Be sure to set "knife Angle
Adjustmant" knob and "Knife
Operation Mode" select
switch to each "Replacing
Knife"Position
Cutting Operation & Knife
Vertical Adjustment
Be sure to set "knife
Operation Mode" select
switch to "cutting"
position
knife Operation
Program Extension
Mode
Replacing
Knife
Cutting
to the cutting mode.
Program Extension Button
Program Forward Button
Memory Delete Button
Repeat/Setup Select Button
In normal operation, this switch must be set to the
repeat mode. The above repeat/Setup Lamp lights up.
The size memory button must be set to the setup mode.
(The above setup Lamp lights up.)
1-7
1-4 Cover Descriptions
Backgauge Cover
M013345-02
Upper Cover
Rear Cover L
Front Cover
Plate L
Table L
Lower Cover
Plate R
Table R
Small Cover
Rear Cover R
Side Gauge R
Front Cover L
Small Cover
Control Box
Side Gauge L
Back Cover B
Back Cover A
Back Cover U
Back Cover L
1-8
1-5 Entering Service Screen
"Normal Cutting" Screen
"Maintenance" Screen
"Information" Screen
"Numeric Keypad" Screen
612
6
2
1
ent
.
ent
05
08
- are not used.)
(
The total counts is memorized on the control P.C.B.
When replacing the control P.C.B.,
1. Write down the total counts before replacing the P.C.B.
2. Replace a new P.C.B.
3.
4. Press the button and input the total count number you wrote down.
CAUTION
Press the buttons.
6 1 2
Total Count Input
Up to five digits can be entered using the
"numeric keypad" screen at once. Input the
numbers the first three digits and the last
four digits separately
When the button is pressed, the
numeric keypad screen appears.
Special Functions
= Total Count Setting
01
= Cutting Program Clear
02
=
Resetting Home Position and
03
Push-out Length to Default
=
Total Count and Count after
04
Replacing Knife
"Service" Screen
Motor Home Position Display
Refer to 1-7 for details.
After replacement, press the button and the [OK] button to clear the total counts of a new P.C.B.
01
Press the button and the [OK] button. Saved cutting programs will be
deleted completely. Deleted cutting programs cannot be restored.
Press the button and the [OK] button. Home positioning value will be
set to 620.0, and the push-out length will be set to 50.0.
Press the button and the [OK] button. Memorized total counts and
count after replacing knife will be set to zero.
04
02
03
04
1-9
1-6 Calibration of Home Position
1. Set the cutting length to 100.0mm.
- This is the temporary value for comparing the
set value with the actual cut length.
2. Cut some sheets.
- Do not align the sheets on the side guide. Align the
sheets only on the backgauge properly, and cut.
3. Measure the dimension of cut sheets.
- Measure the dimension of the sheets by one
decimal place. 100.6mm is given for an example here.
4. Obtain the correction value.
- Correction value is a half of the difference
between the set value and the actual cut length.
- The actual cut length is 100.6mm. Therefore,
the correction value is 0.3mm.
5. Enter a new home position. (Fig.2)
- Show the Backgauge Calibration screen.
(Fig.1, Fig2)
- Add or subtract the correction value which was
calculated in step 4 to or from the current home
position value, and enter the new home position
value. (When the actual cut length is larger than
the set value, substract the correction value.)
In the case of the example, enter the value which
is subtracted by 0.3 and press the button.
The backgauge will move to the new home
position.
6. Check.
- Follow the steps 1 through 3 and check that the
set value matches the actual cut length.
7. Rewrite the home position sheet.
- The home position sheet is attached to the
bottom of the control panel box shown in Fig.3.
Rewrite the new home position on it.
504007
1_6_1A
Fig.1 "Maintenance" Screen
504007
1_6_1B
Fig.2 "Backgauge Calibration" Screen
The home position
sheet is attached to
the bottom of the
control panel box.
504007
1_6_1C
Fig.3 Location of the Home Position Sheet
1-10
1-7 Checking Motor Home Position Distance
504007
1_7_1A
404007
1_7_1B
Home Position Sensor
Sensor Plate
B21
Servo Motor
M20
Explanation of "Home Positioning"
1. At first, the backgauge moves backward and
B21 home position sensor (Fig.2) detects the
sensor plate and turns on.
2. When B21 turns on, the servo motor M20
rotates in the reverse direction and moves the
backgauge forward, and B21 turns off.
3. The motor stops at the position where Z-phase
from the encoder is detected for the first time
in one rotation of M20. This position is the
home position.
- The encoder is housed in M20.
Explanation of "Motor Home Position
Distance"
- The motor home position distance is the
distance between the position which the B21
home position sensor turns off from on and
the position where the Z-phase from the
encoder is detected for the first time in one
rotation of M20. (steps 2 and 3 above).
- One rotation of M20 servo motor is set to 250
in APC-61II. The position of the home position sensor B21 is set so that Z-phase will be
detected at the middle of the motor rotation.
Therefore, the motor home position distance
should be around 125. (Fig.1)
Checking the Motor Home Position
Distance
- The Z-phase cannot be detected correctly
around the area that the B21 home position
sensor turned off from on, and the boundary
line of the first and second rotation of M20.
If the Z-phase appears at these areas, the
encoder may misread it, and
phase which appears next. This will set the
home position to the wrong position.
Therefore, checking the home position dis-
tance is necessary to make sure the encoder
reads Z-phase correctly in the stable area.
detects the Z-
Fig.1 "Service" Screen
Fig.2 Home Position Sensor B21
1-11
This page is intentionally left blank.
1-12
2. Troubleshooting
2-1 blinks on the Display (Backgauge Does Not Operate) .........2-2
2-2 Cut Size is Not Equal ...................................................................2-6
2-3 Knife Does Not Lower (Clamp Does Not Lower Either) ..........2-8
2-4 Knife Does Not Lift ....................................................................2-11
2-5 Clamp Lowers but Knife Does Not Lower...............................2-13
2-6 Clamp Does Not Lower Though Foot Pedal Is Stepped On. ..2-14
2-7 Backgauge Does Not Operate....................................................2-15
2-8 Backgauge Does Not come Forward (But goes backward) ....2-17
2-9 Backgauge Operates By Itself ...................................................2-18
2-10 Nothing Is Shown on Displays.................................................2-19
2-11 Hydraulic Pressure Does Not Operate....................................2-20
2-12 Knife Is Down before Operation........................................... -2-21
2-13 Knife Lower Limit Position Varies .........................................2-22
2-14 Backgauge Does Not Move (61II) ..........................................2-23
2-15 Error Code (61II) .....................................................................2-24
2-1
2-1 blinks on the Display (Backgauge Does Not Operate) Part 1
Why does blink on the display ?
Backgauge is traveled by the screw shaft which is driven by motor. Encoder is installed directly at the back end of the screw shaft, and
the operation distance of backgauge is controlled by counting the number of pulse from the encoder. In case that pulse signal does not
come from encoder while the backgauge is moving, blinks on the display inform to the trouble.
Backgauge is at the front limit position.
When backgauge is at the front limit position
(in normal case about 25mm, when support
plate is fixed about 75mm), limit switch is on.
When turning the power switch on this condition, blinks on the display.
After moving the gauge a little backwards with
adjust knob, turn the power switch on again.
Adjust knob remains being pressed
Adjust Knob
Snap Ring
Spring
Bearing Unit
Micro Switch
In normal case, the adjust knob is pressed by
compression spring to the operation side.
Even if you try to move the backgauge forwards or backwards when the adjust knob
remains being pressed for some reasons, motor
does not drive and
blinks on the display
because the machine is in manual mode.
Shaft of knob is difficult to move.
When the knob does not move smoothly
forwards and backwards, check bearing unit.
Lubricate when movement is dull.
Snap ring unfastens.
When snap ring (STW-20) unfastens, fix it
again.
Compression spring is broken.
When compression spring is broken, replace it
with a new one.
2A2A5A5A5A5
A
High Speed Motor Fuse
Low Speed Motor Fuse
Fuse is blown.
When motor protection fuse is blown, screw
shaft does not operate and no pulse rises from
encoder. Replace fuse according to Ò4-22Ó and
observe it.
2-2
2-1 blinks on the Display (Backgauge Does Not Operate) Part 2
Phase of power is lacking.
Even if one of the three-phases AC power
results in open phase, motor does not operate
and
blinks on the display.
Control Box
1
2
3
4
5
6
T
S
R
Check input voltage which comes to every
section of this terminal board between R-S, ST, and T-R.
When there is no voltage even at one point,
original power is in open phase.
There is problem in control board.
Control
Box
Varistor
1
2
3
4
5
6
SSR
LED
Cement Resistance
Cement resistance is damaged
When switching the motion of the backgauge
(forwards or backwards), short circuit exists
momentarily and this cement resistance can be
damaged. In this case, replace P.C.B.
LEDs from No.1 to No.6 do not turn on.
When LEDs from No.1 to NO.6 showing
operation of knife, clamp, and backgauge turn
on normally, input signals are OK. If there is
no problem in output motor, SSR may has a
problem. Replace P.C.B.
Backgauge belt is cut.
Low Speed Belt
High Speed Belt
Motor Blacket
High Speed Motor
When belt is cut or overturned, power is not
transmitted and screw shaft does not drive.
Therefore, no pulse rises from encoder.
Replace belt with a new one.
As for high speed belt for S/N 103001 or
above, a new wider belt is used which is hard
to overturn. To attach this wider belt to a
previous machine, gauge base and motor base
also must be replaced.
(In case of order, please notice it.)
2-3
2-1 blinks on the Display (Backgauge Does Not Operate) Part 3
Coupling of encoder unit is broken
Screw Shaft
Coupling
Encoder
Set Screws
When coupling is broken or set screws are
loose, rotation of screw shaft is not transmitted
to encoder and no pulse rises.
When coupling is broken, replace it with a new
one.
When set screw is loose, fasten it again.
Adjust knob is heavy
Gauge Rail
Adjust Knob
Fix Nut
Adjust Nut
Screw Shaft
Adjust nut and fix nut prevent screw shaft
returning (backlash) of the backgauge. When
there is problem in screw shaft, nuts or guide,
screw shaft is hard to move and normal pulse
does not rise. Therefore,
blinks on the dis-
play.
Oil on rail and screw shaft is running out.
When oil is running out, lubricate operating
the backgauge for-and backwards to circulate
oil.
There are some foreign objects on rail and
screw shaft.
When there are some foreign objects such as
paper dust, wipe them off and lubricate
enough.
There is problem in encoder.
Encoder is very delicate. When its shaft bends
because of external shock, it does not operate
correctly, even if it is connected with coupling.
Stay
Coupling
Encoder Bracket
Encoder
Screw Shaft
Axis difference or bent of shaft
should be within 0.1mm.
When there is an axis difference as shown in
the drawing, replace not only the coupling but
also the bracket and the stay.
There is contact failure or breaking of cable
from encoder.
Check the voltage between terminal 6 and 8 on
the terminal board 1 (refer to page 7-11) while
rotating the adjust knob slowly.
If the voltage changes
while rotating the knob
signal is output
from encoder normally.
87654
2-4
2-1 blinks on the Display (Backgauge Does Not Operate) Part 4
Motor has burned out
Backgauge is moved by 2 motors. Above all,
high speed motor repeats driving in the normal
and reverse direction according to using condition. For each motor circuit, there is 5A fuse.
However, after using for many years, motor
insulation weaken gradually and motor coil
burns out without blowing of fuse.
Control Box
6
High Speed
TAN-1
5
4
3
2
1
Low Speed
Motor
A2016
VC-1
A 19151311
Motor
14 12
To check motor coil,
For high speed motor:
Check continuity among pins 4, 5, 6 on TAN-1
on control board.
For low speed motor:
Check continuity among terminals 12, 14, 16
on electromagnetic contactor VC-1 in control
box.
Brake surface smuts.
Brake
Encoder
0.15 to 0.3mm
Coupling
Armature
There is a gap between brake and armature for
0.15 or 0.30mm. when brake surface smuts
with metal powder because of surface wear,
semi-brake condition occurs and drive system
of backgauge becomes heavier. In this case,
clutch operation becomes dull and correct
pulse does not rise. Therefore,
blinks on the
display. Remove the metal powder with compression air or wipe off paper.
2-5
2-2 Cut Size is Not Equal Part 1
Backgauge position is determined only by
high speed for- and backward buttons.
When backgauge is operated only using the
high speed forward or backward button, the
backgauge can not stop in the correct position
because of overrun. Determine precious position using low speed forward button or forward operation with adjust knob.
Set screw of coupling is loose.
Brake
Set Screws
Coupling
Encoder
When set screw is loose, rotation of screw
shaft is not transmitted to the encoder accurately, As a result, the size indicated on the
display becomes different from the actual
cutting size.
Adjust it referring to ÒAdjustment of Cut
SizeÓ, from 3-1 to 3-3.
Encoder
Backgauge driving belt is loose.
Low Speed Belt
Motor Bracket
High Speed Belt
3 to 4mm
2 to 3mm
High Speed Belt
High Speed Motor
Motor Pulley
Low Speed Belt
The high speed belt is bent by 2 to 3mm, low
speed belt 3 to 4mm, when the part pointed
with an arrow is pressed by 1kg force.
Tension of high speed belt can be adjusted by
position of motor bracket, low speed motor by
idle pulley. Adjust able range of idle pulley
becomes larger when it is attached upside
down.
2-6
2-2 Cut Size Is Not Equal Part 2
24VDC is not output from power supply.
PW-24
Power Supply PW-24
If output voltage of power supply PW-24 is
too low, the backgauge is delayed moving or
stop and the cumulative defference gets larger.
Check whether there is 24VDC output between 1 and 2 . Check whether there is
100VAC input between 4 and 5 . When there
is not 24VDC output in spite of 100VAC
input, replace power supply.
Gap of clutch or break is not correct.
Operation Side
0.15 to 0.30
0.2 to 0.3
12345
Brake
Gap of brake should be 0.15 to 0.30 mm.
Gap of clutch should be 0.2 to 0.3 mm.
Clutch
When gap of brake or clutch is not in these
ranges, the time lag results in the motion of the
screw shaft. Therefore, defference between
the indicated size on the display and the actual
cut size results.
Adjust it to correct gap.
Or when there is foreign object such as metal
powder on friction surface, remove it with
compression air or wipe off with paper.
2-7
2-3 Knife Does Not Lower (Clamp Does Not Lower Either) Part 1
Cutting button A and B are not pressed
simultaneously.
For safety, when the timing to press cut buttons A and B differs more than 0.5 second, the
machine judges the abnormal operation and
hydraulic system does not operate. Press them
simultaneously (within 0.5 second).
There is a problem with cutting button A or B.
When each of cuttig button is pressed separately and slowly, it sounds click. When there
is no sound, there is mechanical problem or of
switch itself. Replace the cutting button
switch.
The cable from cutting button switch is connected with the machine under the front table.
Disconnect this connector and check the continuity with a tester. If there is the continuity
with cutting button pressed, it is OK. If there is
no continuity, replace cutting button switch.
When LED L2 and L4 on control board (See
Ò7-4 Control BoardÓ) lights for a moment and
go out again at the moment of pressing cutting
button, knife or clamp does not reach to the
upper limit position. See the next description.
Knife is not at the upper limit position.
The cutting operation does not start when
either knife or clamp is not at the upper limit
position. Check the sensor for upper limit
whether knife is at the upper limit position is
observed by sensor.
Front Cover
Sensor
Fixing Blacket
Remove front cover and check whether sensor
lamp is on.
Sensitive Area
Sensor
Lamp
When the lamp is on, knife is at the upper limit
position. When the lamp is not on though
knife is at the upper limit position, put a piece
of metal to sensitive of the sensor. If the lamp
turns on, sensor operates properly. Lower the
sensor bracket.
Clamp is not at the upper limit position.
Control Box
Dock
Lamp Upper Limit Position
Detecting Switch
The limit switch detecting the clamp upper
limit position should be on.
When this actuator is turned to the
right, there must be no detection
sound.
Dock
Lamp Upper Limit Position
Detecting Switch
Or check continuity between 8 and 9 of CON1
on control board with tester.
2-8
1
2
3
4
5
6
2-3 Knife Does Not Lower (Clamp Does Not Lower Either) Part 2
APC-M61
HYDRULIC CUTTER
APC-T61
HYDRULIC CUTTER
There is an obstruction between beam
guards.
Beam Guards
When there is an obstruction on the optical line
between beam guards, the beam is blocked and
safety function operates. Therefore, knife does
not lower.
There is trouble with foot switch control
board.
If board is replaced and problem disappeared,
some of relays on the board has the contact
failure.
Ray
Obstruction
Some of switches on operation panel remains
on.
(APC-M61)
Power
(APC-T61)
Hydraulic
Repeat Setup
Current position
Current Position Display
Backgauge Travel
Put-out
Memory
Presetting
P
S
Presetting
1 2 3 4 5 6
Repeat / Setup
No More
Memory
?
Program No.
Program
Delete
P+-
S+-
Setup
Memory
Program No. Step No.
Step
Memory Delete
Opar Error
?
Step.No.
Memory
Push-out
Step Forward
Size
Memory
Push-out
Memory
Program
Forward
789
456
123
.
0
E
c
Replacing Knife
Be sure to set "knife Angle
Adjustmant" knob and "Knife
Operation Mode" select
switch to each "Replacing
Knife"Position
Cutting Operation & Knife
Vertical Adjustment
Be sure to set "knife
Operation Mode" select
switch to "cutting"
position
knife Operation
Program Extension
Replacing
knife
ON
Mode
Replacing
Knife
Cutting
For APC-M61:
Any of the step forward button, the size
memory button, and the push-out memory
button remains pressed.
For APC-T61:
After button is pressed, there is no sound and it
does not return.
When any of the switches are out of order or
remain pressed, the machine judges that it is in
the setting mode. Therefore, hydraulic system
does not operate.
2-9
There is problem in control board.
Control
Box
Varistor
SSR
LED
Cement Resistance
SSR (solid stay relay) or cement resistance is
damaged.
If its white exterior is broken or cracked because of heat, cement resistance get damaged.
And if there is continuity between the two
parts of the bottom in the following drawing,
SSR is out of order. However, no continuity
does not always mean normal.
If there is continuity,
SSR is out of order.
If this part is damaged, hydraulic pressure is
not applied. Replace the board.
If knife does not lower though hydraulic
pressure applied, check the hydraulic valve.
2-3 Knife Does Not Lower (Clamp Does Not Lower Either) Part 3
Hydraulic valve does not operate correctly.
[Valve Section]
Hydraulic Section
[Electromagnetic Valve]
Remove the apron cover under the table and
check whether LED of electromagnetic valve
turns on, when cutting button is pressed.
LED
Spark Killer
[Top of Electromagnetic Valve]
If LED turns on, the signal comes correctly.
The internal damage of electromagnetic valve
can be considered. Replace electromagnetic
valve.
Grease on clamp rails is not enough to move
the clamp.
Clamp lifts and lowers guided by right and left
rails. However, when there is not enough
grease between clamp and rail, clamp is difficult to move because of metal friction and does
not return to the upper limit position. When the
upper limit position of clamp is not detected,
cutting operation does not start.
Rail
Clamp
Rail
[Back view of the machine]
When there is enough grease on part of
right and left rail, there is no problem. When
there is little grease, lubricate with a grease
gun. (See Ò6-4 LubricationÓ in operation
manual.)
2-10
There is problem in clamp link.
Link A
Sprocket B
Spring
Sprocket A
Clamp
Chain
Hook shaft
Chain
Check the followings.
Chain is damaged.
Sprocket A or B is detached from shaft.
Spring is detached or loose.
(For old model link A) needle bearing is detached. When an old model of the machine has
link A.
When there is problem with any of these parts,
clamp can not be lifted and return to the upper
limit position. When clamp is not the upper
limit position, the machine can not start cutting
operation.
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