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Wood-mizer 096009, Safety, Operation, Maintenance & Parts Manual

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Wood-mizer 096009 Safety, Operation, Maintenance & Parts Manual Download Page 24

Troubleshooting

Error Messages

5

5-1

ITSdoc112009

Troubleshooting

SECTION 5   TROUBLESHOOTING

5.1

Error Messages

See Table 5-1.   

The possible error messages and their causes are listed below:

MESSAGE

CAUSE

SOLUTION

Error --- A/D
A/D Failure

Power supply failure. 

A/D module has broken. 

Linear sensor is out of range.

Check connecting cable.

Check the A/D module connections. Replace if 
necessary.
Adjust the linear sensor. 

See Section 4.1

Error --- IDX
Home Sensor

Circuit breaker failure. 

Proximity sensor is not adjusted. 

Index motor is not plugged.

Check the 3 Amp circuit breaker located at rear of 
the setter. Turn on the circuit breaker or replace if 
necessary.

Adjust the proximity sensor.

Plug the indexer motor.

Error --- IDX
Not Fully Seated

Indexer is not seated properly. 
(Proximity sensor light is off). 

Adjust the indexer assembly. Check if the proxim-
ity sensor light is on.

Error --- CAM
Home Sensor

Circuit breaker failure. 

Cam proximity sensor not adjusted

Cam motor is unplugged.

Check the 3 Amp circuit breaker located at rear of 
the setter. Reset the circuit breaker or replace if 
necessary.

Adjust cam proximity sensor. Check if the proxim-
ity sensor light is on.

Plug the cam motor.

Error --- Cal
Clamp Zero CAL Block

While calibrating: metal pattern 
block is not clamped.

Clamp the metal pattern block to adjust the sen-
sor pin.

Error --- Cal
Sensor Out of Range

Linear sensor is out of range.

Adjust the linear sensor. 

See Section 4.1

Error -- Sensor
Return Zero

Sensor pin is stuck.

Inspect the sensor pin. Clean the sensor if neces-
sary.

Error --- Bld
Tooth Set

Tooth set is incorrect.

Adjust the pusher. Inspect the blade.

Error --- Bld
Set Pattern

Tooth set pattern is not correct. 

Inspect the blade teeth. Correct the teeth pattern.

Lower Set Limit >=
Upper Set Limit

Lower tooth set limit is above the 
upper limit.

Increase the upper tooth set limit. OR decrease 
the lower tooth set limit.

Raker Limit >=
Lower Set Limit

Raker limit is above the lower limit. Increase the lower tooth set limit. OR decrease 

the raker tooth set limit.

TABLE 5-1

Summary of Contents for 096009

Page 1: ...hsetter Safety Operation Maintenance Parts Manual 096009 rev A 00 Safety is our 1 concern Read and understand all safety information and instructions before oper ating setting up or maintaining this machine Form 1032 ...

Page 2: ...fication 1 11 SECTION 2 OPERATION 2 1 2 1 Machine Setup 2 1 2 2 Preliminary Setup 2 3 2 3 Machine Operation 2 5 SECTION 3 MAINTENANCE 3 1 3 1 Setter Calibration 3 1 3 2 Miscellaneous 3 1 SECTION 4 ALIGNMENT 4 1 4 1 Sensor Adjustment 4 1 SECTION 5 TROUBLESHOOTING 5 1 5 1 Error Messages 5 1 SECTION 6 REPLACEMENT PARTS 6 1 6 1 Pivoting Index Assembly 6 1 6 2 Pivoting Index Motor Assembly 6 3 6 3 Cam ...

Page 3: ...Table of Contents Section Page Table of Contents doc112009 iii SECTION 7 ELECTRICAL INFORMATION 7 1 7 1 Electrical Symbol Diagram 7 1 ...

Page 4: ...any equipment marked with warning stripes Read and observe all safety instructions before operating this equipment Also read any additional manufacturer s manuals and observe any applicable safety instructions includ ing dangers warnings and cautions Always be sure that all safety decals are clean and readable Replace all damaged safety decals to prevent personal injury or damage to the equipment ...

Page 5: ... in place and secured before operating the toothsetter Failure to do so may result in serious injury DANGER Keep all persons away from moving parts when operating this machine Failure to do so will result in serious injury DANGER Always keep hands away from moving bandsaw blade Failure to do so will result in serious injury WARNING Always wear eye protection when operating this machine Failure to ...

Page 6: ...s and exposure levels it is not possible to determine with certainty if preventives are needed or are not needed The factors affecting a current level of noise exposure during work are inter alia room characteristics and characteristics of other noise sources e g number of machines and machining operations nearby Also the permissible exposure level value may vary depending on country This informat...

Page 7: ...mation Safety SISdoc112009 1 4 1 1 7 Setter Components See Figure 1 1 The major component and dimensions of the Automatic Setter are listed below FIG 1 1 SI0001B Blade Support Tube Cam Index Motor Cam Drive Motor Control Panel Blade Height Adjustment Air Valve ...

Page 8: ... used to clear an error Stop Pause press to stop or pause machine Menu press once to get to the menu Up arrow press to select menu or option used to increase values Down arrow press to select menu or option used to decrease values Clear Abort press once to clear the setting cancel your action or clear an error Enter press once to confirm your choice FIG 1 2 MENU CLEAR ABORT ENTER F1 Clamp F2 Manua...

Page 9: ...next tooth F3 Manual Bend used to bend the blade teeth manually regardless of set the tooth set is not checked F4 Single Cycle press to set the blade using the single cycle mode The indexer pawl moves the blade The blade is clamped and the tooth set is checked The setter sets the tooth if necessary F5 Zero Calibrate used during calibration of the blade clamp See Section 3 1 Setter Calibration ...

Page 10: ... It doesn t apply this toothsetter version Pattern Single Clamp The mode similar with the Set Single Clamp mode but the setter checks the teeth pattern See System Parameters for how to set the maximum number of pattern errors only 1 in most cases When the num ber of possible errors is exceeded the setter stops the setting process and the Error Blade Set Pattern message appears It doesn t apply thi...

Page 11: ...he limit value The upper set limit is the upper limit of the tolerance for the blade tooth set If the tooth set exceeds the upper limit the setter adds the tooth to the group of teeth with the incorrect set The setter stops when the number of set errors is exceeded Lower Set Limit The desired tolerance for the lower set When entered the Lower Set Limit appears Use the UP and or DOWN arrows to set ...

Page 12: ...4 158 10 S 042 180 0 020 20 0 0 022 22 0 0 009 9 0 274 158 9 S 042 180 0 019 19 0 0 021 21 0 0 009 9 0 275 158 9 S 042 180 0 020 20 0 0 022 22 0 0 009 9 0 375 158 10 S 045 180 0 024 24 0 0 026 26 0 0 009 9 0 375 158 9 S 045 180 0 020 20 0 0 022 22 0 0 009 9 0 376 158 13 S 045 180 0 024 24 0 0 026 26 0 0 009 9 0 376 158 10 S 045 180 0 024 24 0 0 026 26 0 0 009 9 0 376 158 9 S 045 180 0 020 20 0 0 0...

Page 13: ...ooth Set message appears The mark is the current tooth set NOTE To decrease set bend the tooth back with the slot in the cor rection tool provided Press the green Start Resume button to cancel the error Push the F3 Manual Bend button to allow the setter to set the tooth again To add set press the F3 Manual Bend button Dpy Imperial MM when selected the Standard Selected appears followed by the cur ...

Page 14: ...s Indexer Home Prox indicates the indexer cam proximity sensor status Cam Home Prox indicates the drive cam proximity sensor status Linear Sensor Adjust indicates the linear sensor adjustment status See Section 4 1 Sensor Adjustment for the adjustment procedure System Tooth Counter indicates the total number of blade teeth processed The bot tom line shows the last four digits of the number The upp...

Page 15: ... the blade on the setter stand Position the three adjustable blade guide supports so they lightly touch the inside of the blade The adjust able guides should lightly support the blade and keep it from wobbling 2 Use the blade height knob to adjust the blade height so the bottom of the gullet is aligned with the top of the blade clamps See Figure 2 1 FIG 2 1 Blade Height Adjustment Knob Pusher Adju...

Page 16: ...s or hand when turning the cam DANGER Keep all persons away from moving parts when operating this machine Failure to do so will result in serious injury 4 Adjust the index ramp The push pawl should push one tooth at a time To adjust loosen the blade ramp set screw Slide the blade ramp as necessary and retighten the set screw The pawls should contact the point of the tooth where the face and gullet...

Page 17: ...embly 2 Make sure the voltage selector plate is set properly before turning on electrical power to the setter 3 Plug the power cord in the socket at the rear of the setter 4 Locate the air assembly at the rear right side of the setter Connect the incoming air sup ply line to the fitting Make sure the air gauge indicates 60 P S I Adjust the pressure if needed To adjust the pressure lift the black c...

Page 18: ...9 Operation See Figure 2 2 5 Turn the ON OFF switch to the ON position 6 Calibrate the setter if necessary See Section 3 1 Setter Calibration 7 Make all the adjustments necessary to start the setting operation See Sections 1 6 through 1 8 FIG 2 2 ...

Page 19: ...he adjustments have been made Push START to begin the setting operation All values will remain as set 5 Toothsetter works automatically To adjust the pusher adjustment knobs push the CLAMP button Tooth bend value will appear on the display This value should be between upper and lower set limit If it will be smaller turn the pusher adjustment knob to adjust as small value as possible Next hold down...

Page 20: ...n 2 2 6 SISdoc112009 Operation 6 The machine will automatically stop after the setting operation has been completed 7 Remove the blade and invert it 8 Swing the index motor assembly to the other side Repeat the setting operation ...

Page 21: ...f the Error CAL Clamp Zero CAL Block message appears you need to adjust the sensor first See Section 4 1 Sensor Adjustment for the adjustment procedure 6 With the calibration plate still clamped manually retract the sensor pin and insert the 024 diameter gauge pin between the calibration plate and the sensor pin If the display does not indicate 024 001 the sensor is malfunctioning and should be re...

Page 22: ...ate as thick as the blade you want to set Keep the upper edge of the plate and the sensor pin level 4 Press the MENU button Push the UP arrow once to enter the DIAGNOSTIC SETUP menu and press the ENTER button Press the UP button once to select the LINEAR SENSOR ADJUST menu Press ENTER again to confirm See Figure 4 1 The sensor is adjusted properly if the black mark is located between the arrows on...

Page 23: ... sensor Move the linear sensor back and forth to place the black mark between the arrows on the display 7 Tighten the mounting screws to secure the linear sensor when adjustment is complete 8 Press CLEAR ABORT to leave the adjustment option FIG 4 2 Remove the two screws and the sensor guard SI0005B Loosen the bolts to adjust the sensor Move the linear sensor check the display while adjusting ...

Page 24: ... failure Cam proximity sensor not adjusted Cam motor is unplugged Check the 3 Amp circuit breaker located at rear of the setter Reset the circuit breaker or replace if necessary Adjust cam proximity sensor Check if the proxim ity sensor light is on Plug the cam motor Error Cal Clamp Zero CAL Block While calibrating metal pattern block is not clamped Clamp the metal pattern block to adjust the sen ...

Page 25: ...Troubleshooting Error Messages Troubleshooting ITSdoc112009 5 2 5 ...

Page 26: ...cket Head Stainless Steel F05005 70 4 4 Plate Upper Index Support 037995 1 5 Bolt 5 16 18 x 3 4 Flat Socket Head F05006 95 4 6 Spacer Index Arm 037996 1 7 Arm Wldmnt Index Pivot 037998 1 8 Block Index Motor Support 035503 1 9 Washer 5 16 Split Lock F05011 13 4 10 Bolt 5 16 18 x 3 4 Hex Head Grade 2 F05006 5 4 11 Bolt 3 8 16 x 2 Full Thread Carriage Head F05007 22 1 12 Washer 3 8 SAE Flat F05011 3 ...

Page 27: ... 3 4 O D Rubber 035523 1 21 Proximity Sensor 8mm Inductive Shid 050084 2 22 Block Index Arm Pivot 035469 2 23 Screw 5 16 18 x 2 Socket Head F05006 87 4 24 Spacer Bearing S32032 2 25 Ring 7 8 Inside Retaining F04254 23 1 26 Bearing R6 2NSL SRI 2 ABEC 1 P10688 5 27 Nut 3 8 16 Hex Lock F05010 25 1 28 Plate Index Mounting 037994 1 29 Washer 5 16 SAE Flat F05011 17 8 30 Washer 5 16 Split F05011 13 8 31...

Page 28: ...Socket Head F05004 61 4 4 Bolt 10 32 x 5 8 Hex Head F05004 152 4 5 Washer 10 Split Lock F05011 20 4 6 Shaft SAS Drive 035475 1 7 Screw 10 32 x 1 4 Socket Head F05004 67 2 8 Grip 5 8 I D Hand 004742 1 9 Housing SAS Bearing 035476 1 10 Handle Index Pivot 035522 1 11 Bracket Index Proximity Sensor 035499 1 12 Proximity Sensor 8mm Inductive Shid 050084 1 13 Bolt 1 4 20 x 1 2 Hex Head F05005 15 2 14 Wa...

Page 29: ...ket Head Cup Point Set F05005 47 2 19 Plate SAS Cam 060413 1 20 Nut 3 4 10 Nylon Lock Half F05010 122 1 21 Bolt 1 4 20 x 1 2 Socket Head F05005 39 2 22 Shaft SAS Index Pivot 035482 1 Pawl Assy SAS Push 035498 1 23 Block SAS Push Pawl 035489 1 24 Nut 3 8 24 Hex F05010 123 1 25 Pawl Weldment SAS Push 035488 1 26 Bearing 1 2 I D Needle P30253 1 27 E clip 1 2 Shaft P10649 1 28 Fitting 1 4 28 Grease P0...

Page 30: ...1 4 4 Bolt 10 32 x 5 8 Hex Head F05004 152 4 5 Washer 10 Split Lock F05011 20 4 Housing Assembly SAS Bearing 035479 1 6 Housing SAS Bearing 035476 1 7 Riser Cam Housing S35047 1 8 Bolt 5 16 18 x 2 1 2 Socket Head F05006 60 4 9 Bracket Index Proximity 035520 1 10 Proximity Sensor 8mm Inductive Shid 050084 1 11 Bolt 1 4 20 x 1 2 Hex Head F05005 15 2 12 Washer 1 4 Split Lock F05011 14 2 13 Shaft SAS ...

Page 31: ...Lock Half F05010 122 1 21 Bolt 1 4 20 x 1 2 Socket Head F05005 39 2 ARM ASSEMBLY PUSHER PIVOT A32054 1 22 Arm Weldment Cam Pivot 032349 1 23 Block Pivot S32033 2 24 Bolt 3 8 16 x 1 Socket Head F05007 52 1 25 Bearing R6 2NSL SRI 2 ABEC 1 P10688 8 26 Spacer Pusher Arm S32053 2 27 Bolt 3 8 16 x 1 1 4 Socket Head F05007 150 1 28 Bolt 3 8 16 X 3 1 2 Socket Head F05007 111 1 29 Spacer Bearing S32032 2 3...

Page 32: ...65 1 5 Screw 1 4 20 x 3 8 SHCP Set F05005 47 2 6 Spring 6 Dia Compression 510 Id x 3 4 032377 1 7 Pin Pusher ReSharp 032362 R 1 8 Bracket Pusher Pin Channel 032361 1 9 Pin Clamp S32018 1 10 Insert 3 4 Carbide Clamping P32010 1 11 Bolt 10 24 x 1 2 Flat Socket Head F05004 61 1 12 Clamp Wldmt Front 032374 1 13 Bushing 5 16 ID x 1 2 OD x 1 2 Drill Jig P32076 1 14 Plate Pusher Top SAS 035502 1 26 27 28...

Page 33: ... 16 18 x 3 1 4 Socket Head F05006 59 4 32 Gusset Clamp Support 035461 1 2 33 Bolt 5 16 18 x 2 3 4 Socket Head F05006 67 2 34 Bolt 5 16 18 x 1 1 2 Socket Head F05006 66 2 35 Guard Top Sensor 035789 1 36 Screw 10 24 x 3 8 Socket Head F05004 78 2 37 Block Sensor Mount 035791 1 38 Bolt 10 24 x 1 Socket Head F05004 2 4 39 Bolt 10 24 x 1 2 Flat Socket Head F05004 61 1 40 Insert 3 4 Carbide Clamping P320...

Page 34: ...ement Parts Front Back Clamp Assembly 6 6 9 SIdoc112009 Replacement Parts 56 Fitting 1 8 MPT x 1 4 Tube Swivel Elbow Air P09736 2 Pin 024 Dia Gauge Not Shown 035730 1 Strip 0700 Calibration Not Shown 032165 1 ...

Page 35: ...BOLT 5 16 18 X 3 4 SOCKET HEAD F05006 63 5 CYLINDER ASSEMBLY CLAMP 032919 1 6 Cylinder 3 1 4 Bore x 1 2 Stroke Air P32034 1 7 Fitting 3 8 NPT X 3 8 90 Air P21526 2 8 Nut 1 2 13 Hex Jam F05010 31 1 9 Block Clevis S32081 1 10 E clip 3 8 Shaft P10689 2 11 Pin Clevis S32083 1 ARM ASSEMBLY CLAMP A32031 1 12 Arm Clamp Pivot S32029 1 13 Bearing R6 2 NSL SRI 2 ABEC 1 P10688 2 14 Spacer Bearing S32032 2 15...

Page 36: ...der Clamp Assembly 6 6 11 SIdoc112009 Replacement Parts 17 Bolt 3 8 x 2 1 4 Shoulder 5 16 18 Thread F05006 116 1 18 Washer 3 8 Flat F05011 3 1 19 Nut 5 16 18 Hex Lock F05010 6 1 20 BOLT 5 16 18 X 1 3 4 SOCKET HEAD F05006 65 4 ...

Page 37: ...gulator R384 01C 300 PSI Air Flow P02765 1 2 Fitting 1 8 NPT X 3 8 Tube Straight P21553 1 3 Fitting 1 8 Dry Seal Nipple P02764 1 4 Gauge 160 PSI P02766 1 5 Filter F504 01DH P02769 1 6 Fitting 1 8 NPT Male Air Coupler P22681 1 7 Bolt 1 9 16 I D U S03062 1 8 Nut 1 4 20 Self Locking Hex F05010 9 2 9 Fitting 1 8 NPT Street T 032166 1 10 Fitting 1 8 MPT x 1 4 Tube Swivel Elbow Air P09736 1 1 2 3 4 5 6 ...

Page 38: ...3 Bolt 1 4 20 x 1 Socket Head F05005 89 2 4 Washer 1 4 Split Lock F05011 14 2 5 Ramp SAS Left Index S32094 1 6 Bolt 10 24 x 1 2 Socket Head F05004 26 1 7 Pin 3 16 x 1 2 Roll F05012 35 1 8 Pin Blade Wear S32105 1 9 Bolt 10 24 x 1 1 4 Socket Head F05004 31 1 BLOCK ASSEMBLY SAS RIGHT HAND INDEX 035500 1 10 Block SAS Index 035449 1 11 Block SAS Blade Guide 035454 1 12 Bolt 1 4 20 x 1 Socket Head F0500...

Page 39: ...T 035528 1 21 Knob Blade Adjuster 032912 1 22 Screw 1 4 20 x 3 8 Socket Head Cup Point Set F05005 47 1 23 Block Height Adjustment S32099 1 24 Adjuster Weldment SAS Rear 035526 1 25 PLATE WASHER RETAINER S32100 1 26 BOLT 5 16 18 X 1 SOCKET HEAD F05006 19 2 27 WASHER 5 16 SPLIT LOCK F05011 13 2 28 WASHER 3 8 ID X 7 8 OD X 1 4 FELT P32102 6 BLOCK ASSEMBLY BLADE HEIGHT ADJUSTMENT A32103 2 29 Block Hei...

Page 40: ...ssembly SAS 050060 1 3 Bolt 8 32 x 5 8 Socket Button Head Stainless Steel F05004 98 2 4 Nut 8 32 Self Locking F05010 41 2 5 Transformer Assembly 115 230 Pri 12 24 Sec 050086 1 6 Bolt 10 24 x 3 8 CrSl PH F05004 3 13 1 2 3 4 5 6 6 6 6 SI0022 2 9 7 8 3 10 11 12 13 13 14 15 17 18 19 13 15 20 7 21 22 23 21 7 24 25 26 27 28 29 29 30 31 32 33 34 35 36 37 38 39 40 44 41 56 57 58 57 59 57 60 61 62 57 62 23...

Page 41: ...Clamp 5 8 EMT Coated 010748 4 24 Foot Rubber P06104 4 25 Bolt 8 32 x 1 2 S1 Hex Head F05015 18 4 26 Module Assy Power Entry 050073 1 27 Breaker 3 Amp Panel Mount E10466 1 Valve Assy SAS Air 035517 1 28 Valve 4 Way 24V Air Solenoid 035516 1 29 Fitting 1 4 NPT x 3 8 90 Air P21521 2 30 Muffler 1 4 NPT Air P20904 1 31 Fitting 1 4 Npt X 1 4 Air 90 Deg P21519 1 32 Connector 5 Hole 064 210 Cord E23494 1 ...

Page 42: ...w 32 x 1 1 4 Socket Head F05004 225 2 50 Terminal Block 1 Tier Phoenix 024893 1 Valve Assy SAS Air 037985 1 51 Valve 4 Way 24V Air Solenoid 035516 1 52 Muffler 1 4 NPT Air P20904 2 53 Fitting 1 4 Npt X 1 4 Air 90 Deg P21519 3 54 DECAL SAS SERIAL PLATE 035529 1 55 DECAL SERIAL PLATE OVERLAY 035532 1 56 PANEL CONTROL BOX SERVICE RIGHT SIDE 035512 1 57 BOLT 1 4 20 X 3 8 SOCKET BUTTON HEAD F05005 62 2...

Page 43: ...4 20 Self Locking Hex F05010 9 1 6 Nut 1 4 20 Wing F05010 13 1 7 BLOCK SAS BLADE SUPPORT ARM MOUNTING 035777 3 8 BOLT 3 8 16 X 1 3 4 HEX HEAD FULL THREAD F05007 19 3 9 WASHER 3 8 SPLIT F05011 4 3 10 STOP PLATE WELDMENT INDEX RIGHT HAND 035494 1 11 BOLT 5 16 18 X 3 4 HEX HEAD F05006 5 4 12 WASHER 5 16 SPLIT LOCK F05011 13 4 13 WASHER 5 16 SAE FLAT F05011 17 4 14 PLATE WELDMENT INDEX LEFT HAND STOP ...

Page 44: ...SIdoc112009 Replacement Parts 18 NUT 1 4 20 SELF LOCKING HEX F05010 9 8 19 SCREW 5 16 18 X 3 4 SOCKET HEAD F05006 63 4 20 BOLT 3 8 16 X 1 1 2 HEX HEAD F05007 17 2 21 NUT 3 8 16 HEX JAM F05010 29 2 22 SPACER 25 64 I D X 3 4 O D X 1 2 LONG S22625 3 ...

Page 45: ...C 30VA 50 60Hz C0 C2 X0 X1 X2 X3 X4 X5 V Y0 Y1 Y2 Y3 Indexer Right Pos Indexer Left Pos Indexer Home Cam Start Stop D0 05DR DIRECT 05 LOGIC Display Terminal OP 620 Right Cam Left Clamp A1 A2 A1 A2 A1 A2 A1 A2 1 3 2 4 24V DC F0 04AD 1 1 2 3 4 Analog Input 4 20mA 0 20mA 1 2 BALLUFF M1 M2 X6 Y4 1 5 2 6 12 8 11 7 24V K3 F 1 2 K3 G R1 F1 1 2 K2 A K2 B K1 B K1 A 1 2 1 2 R1 R1 R2 Index Cam P1 A1 A2 P1 11...

Page 46: ...setter calibration 3 1 O operation machine operation 2 5 machine setup 2 1 preliminary setup 2 3 R replacement parts air regulator 6 12 blade support arms 6 18 cam drive unit 6 5 control base 6 15 cylinder clamp 6 10 front back clamp 6 7 pivoting index 6 1 pivoting index motor 6 3 rear adjuster blade height index ramp 6 13 S schematics 7 1 setup site preparation 1 11 T troubleshooting error messag...

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