Norfield magnum Operator'S Manual Download

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OPERATOR’S

MANUAL

Release:

SIGNATURE SERIES

MAGNUM

Effective S/N:

DJ-2832-95

Document Number:

17-350

Summary of Contents for magnum

Page 1: ...OPERATOR S MANUAL Release 1 SIGNATURE SERIES MAGNUM Effective S N DJ 2832 95 Document Number 17 350 ...

Page 2: ...2 First Release September 2008 ...

Page 3: ...ice We have been dedicated to providing quality products and excellent customer service for more than 40 years Norfield Industries has earned a repu tation in the pre hanging industry for setting standards for reliable machinery full techni cal support machine parts full line industrial woodworking tools and supplies and a team of customer care representatives to support you Our factory trained te...

Page 4: ...on of Major Components Section 1 Installation Setup Section 2 Operation Section 3 Settings Adjustments Section 4 Special Adjustments Section 5 Maintenance Section 6 Troubleshooting Warranty Parts Replacement Policy Contact Information 5 8 10 12 14 18 23 35 52 55 66 67 ...

Page 5: ...tuation which if not avoided COULD result in death or serious injury Caution indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury It may also be used to alert against unsafe practices Caution without the safety alert symbol indicates a poten tially hazardous situation which if not avoided MAY result in property damage but not personal injury Notic...

Page 6: ...determined that a noise level in excess of 85dB aver age in 8 hours can cause permanent hearing damage We recommend that hearing protection be worn even if the decibel level is below 85dB Certain types of wood dust can cause allergic reactions Sawdust has been determined to be a Group A carcinogen by the International Agency for Re search on Cancer IARC A dust collection system or an approved pers...

Page 7: ...s have come to a complete stop Do not attempt to clean material from this machine until all the cutting blades have come to a complete stop Even when the machine has been turned to the off position it may take up to several minutes for the blades to coast down to a complete stop Woodworking machinery is inherently dangerous common sense and good safety practices are your best defense against injur...

Page 8: ...or circuits each employee will place their own personal lock on the energy isolating devices A lock for each individual involved is the preferred method for locking out energy sources If this not feasible the designated in dividual to the work crew e g the project Supervisor or Foreman with complete knowl edge of who is on the crew may be designated by the work crew as the individual re sponsible ...

Page 9: ... a check on having disconnected the energy sources operate the push button or other normal operation controls to make certain the equipment will not operate In the event that electrical circuits have been locked out insure that the circuits are de energized by applying an appropriate voltage tester that itself has been tested on live circuits Be sure to return all operating controls to the neutral...

Page 10: ...Volts Amps Lock Drill Norfield 6801 021 2 208 230 5 9 5 9 Latch Drill Norfield 6802 032 1 208 230 3 1 2 8 Sander Baldor 15 176 1 208 230 3 1 2 8 Cutterhead Baldor 15 178 5 208 230 12 9 11 7 Elevator Dayton 15 154 1 3 208 230 1 7 1 7 3 Phase Motor Specifications Application Motor Part Number HP Volts Amps Powerfeed Dayton 15 360 1 15 DC Volts 75 Butt Router Motor Dewalt 15 174 1 1 2 115 11 Faceplat...

Page 11: ... 3 8 2 1 4 Jamb Width 2 1 2 to 10 1 2 Jamb Length Up to 9 0 Jamb Thickness 1 2 1 5 8 Stop Thickness 1 2 Maximum Butt Spacing Variable 6 1 2 Minimum from top of Door Butt Radius 1 4 5 8 Butt Size Standard 3 1 2 4 4 1 2 5 Optional 3 Lock Backsets 2 3 8 to 5 Machine Capabilities ...

Page 12: ...805 115 ASSEMBLY ASSEMBLY TRAM RAIL UNDERCUT REFERENCE DOOR CLAMPS INFEED BED FACEPLATE ROUTER ASSEMBLY LOCK DRILL LATCH DRILL POWERFEED ASSEMBLY OPERATOR CONTROL PANEL FOOT PEDALS DOOR CLAMP DRILL CYCLE GENERAL ASSEMBLY FRONT AND JAMB STOPS CUTTERHEAD JAMB CLAMP REFERENCE ASSEMBLY LOCATION OF MAJOR COMPONENTS ...

Page 13: ...REGULATOR LUBRICATOR TRAM RAIL T TRACK ASSEMBLY MAIN ELECTRICAL PANEL UNDERCUT REFERENCE ASSEMBLY BELT GUARD AXILIARY ELECTRICAL PANEL 6807 028 ASSEMBLY WIDTH INDEX MOTOR 13 668 LOCK DRILL LIFTING BRACKET FACEPLATE ROUTER ASSEMBLY GENERAL ASSEMBLY REAR ...

Page 14: ...following procedure is recommended 1 Remove the wood framework and plastic covering 2 With the machine still on the base move it close as possible to its permanent location Rollers can be placed under the crate base that it can be moved into position easily 3 Remove the bolts securing the machine to the base and lift the machine into position 1 2 SHIPPING DAMAGE AND SHORTAGES After the machine has...

Page 15: ...cal enclosures and components on the rear of the machine Material flow in and out of the machine also needs to be considered On the infeed end of the machine a minimum of 8 clearance is recommended for loading doors On the outfeed end at least 4 is recom mended for material removal If a portable dust collector is being used placement of the machine should allow adequate space for the unit FIGURE 1...

Page 16: ...has the mo tor turning COUNTER CLOCKWISE when viewed from the front of the machine If the rotation is not correct have the electrician reverse the two outside leads on the three phase input THREE PHASE CONNECTION CON NECT HIGHEST VOLTAGE LEG TO CENTER LUG MAIN ELECTRICAL PANEL FIGURE 1 3 1 4 AIR SUPPLY AND CONNECTIONS The Magnum requires 2 2 CFM of clean dry air 90 PSI 8 5 CFM if air screwdriver a...

Page 17: ...ack of the machine on the lower frame support see Figure 1 2 If the Norfield Vacuum unit was purchased with this machine a cord end is provided on the backside of the machine 230V Phase 3 10A for automatic starting Allow adequate space for access to the dust bags and controls of the vacuum system The vacuum unit may be placed behind or at either end of the Magnum depending on the layout of your sh...

Page 18: ... of the faceplate rout Proper procedures for making these adjustments are outlined in Section 4 Refer to figure 2 1 below for adjustment locations SANDER BUTT ROUTER 1 0 DOOR SUPPORTS HARDWARE TRAY 6807 113 6805 127 INDEX BAR DOOR MAIN BAR DOOR ROLLERS 6805 115 ASSEMBLY ASSEMBLY TRAM RAIL UNDERCUT REFERENCE DOOR CLAMPS INFEED BED FACEPLATE ROUTER ASSEMBLY LOCK DRILL LATCH DRILL POWERFEED ASSEMBLY ...

Page 19: ... inch increments and at your pre set door undercut The other method is used to set the ma chine for any door width between 1 6 and 4 0 by reading the door width scale see figure 2 1 Move the top section in the direction needed to obtain the correct setting by the FAST switch in either the UP or DOWN position When you are approximately 1 2 inch to 1 4 inch below the desired door width rotate the SL...

Page 20: ...tion on the jamb rack right or left hand by pushing the dado end against the appropriate jamb stop 8 By this time the first door will be waiting in the drill section Roll it against door stop at the same end as the jamb is located While pressing the door against the main bar and the door stop operate the foot pedal to clamp the door 9 Start the drill cycle by depressing the foot pedal located to t...

Page 21: ...raise the carriage up until it locks 13 Apply the hinges 14 Unclamp the door and fold the jamb toward you Roll the door until the lock bore is over the face plate template then activate the stop by pulling the faceplate handle out away from the frame This will activate the locating cone 15 Push the door against the main bar turn on the faceplate router and clamp the door by pushing the button in t...

Page 22: ...22 THIS PAGE IS DELIBERATELY LEFT BLANK ...

Page 23: ...3 9 Header Clearance 3 10 Changing the Lock Bit 3 11 Changing the Latch Drill Bit 3 12 Changing the Lock Bore Back Up Block 3 13 Sander Adjustment 3 14 Changing the Butt Spacing 3 15 Changing Mortise Size 3 16 Changing Mortise Radius 3 17 Mortising Flat Jambs 3 18 Mortise Depth 3 19 Butt Router for Exterior Jamb and Mullions 3 20 Machining 1 0 1 4 Doors 24 24 25 25 25 26 27 27 28 29 29 29 29 30 31...

Page 24: ...ush the knob back in to lock the setting REGULATOR ADJUSTMENT KNOB FIGURE 2 3 LUBRICATOR ADJUSTMENT KNOB LUBRICATOR BOWL PARTICULATE FILTER COALESCING FILTER Set the drop type lubricator so that two to four drops of oil is mixed with the air supply every minute Adjustment is accomplished with the adjustment knob which is located next to the oil fill port Turning the knob counter clockwise increase...

Page 25: ...t of the machine CAUTION There should be no doors in the machine when this adjust ment is made To raise or lower the top section rotate the FAST switch to either the UP or DOWN position as necessary and watch the scale until you are approximately 1 4 below the width setting you want then rotate the SLOW switch to the UP position and release it The top section will go up slow and stop at the next d...

Page 26: ...attempting a large undercut the cutterhead must be SHARP and the cutterhead V belt must be TIGHT It is recommended that you use the slower powerfeed speed settings when large undercuts are made The machine is factory set for a specific undercut of 1 8 The undercut scale located on the side of the left width carriage displays the undercut the machine is set for Next to the scale is the undercut adj...

Page 27: ... reach the lock bore hole this is simply accomplished by the LATCH STROKE selector switch mounted on the operator control panel As a rule when the backset is changed to any setting greater than 3 the particle board drill back up block will also have to be changed to prevent tear out of the lock bore BACKSET ADJUSTMENT CRANK Lock height is defined as the distance from the center of the lock bore to...

Page 28: ...ts the door unclamp the door this will return and reset the drill cycle Remove the door from the machine and measure from the top of the door to the drill mark left on the door by the bit 7 Adjust the door stop screw until you have achieved 44 or the dimension you desire FIGURE 3 6 1 16 TO 1 8 HEADER CLEARANCE DOOR STOP JAMB STOP FIGURE 3 5 LOCKING SCREWS DOOR STOP ADJUSTMENT JAMB STOPS INDEX BAR ...

Page 29: ...tch drill of your machine is a single fluted flat type drill bit To remove this bit use a adjustable wrench secured across its flats to keep it from turning while you use a 1 1 4 wrench on the flats on the latch drill chuck to break loose the tightened threads The bit can then be unscrewed by hand As an option a double fluted twist type drill bit is available To remove it it is necessary to insert...

Page 30: ...5 Lower router carriage until the locating dog on the router carriage is over the index block nearest the top of the door and the router carriage is resting on the door 6 Slide router carriage back and forth until the applicable butt reference line on the door clamp bar is properly aligned with the mark on the door nearest the top of the door see figure 3 7 7 Move the door while holding the stop t...

Page 31: ...E RADIUS Mortise radius is determined by the diameter of the router bit being used A 1 2 diameter bit will produce a 1 4 radius and a 1 1 4 router bit will produce a 5 8 radius If the router carriage is going to be changed from one radius to another the following applies 1 Change the stop screws in the stop turret use 10 24 x 3 4 flat head screws for 1 4 radius or 10 24 x 1 flat head screws for 5 ...

Page 32: ... Stop Dog stop system is generally used for 3 1 2 hinges only If you have need to mortise for 4 or other sized hinges on jambs with no stop applied it is recommended you purchase an extra flat jamb stop assem bly and set it for the required mortise dimensions To change mortise depth open the locking clamp lever and position the zero on the adjustment ring exactly above the pointer on the router ba...

Page 33: ...ows 1 Raise the rear of the carriage to the top most position and engage the upper indexing pins 2 Replace the standard index dog 6809 006 with the extended index dog provided in boxed parts 6805 090 The extended stop dog must be installed with the sloped surface towards the operator similar to the manner that the standard dog was installed 3 To operate the router in this configuration the width i...

Page 34: ...mbly above the regular rollers See Figure 3 11 3 Place the door on the 1 0 rollers set it against the door stop and pull the bottom edge of the door out against the flanges on the rollers this will ensures that the door is vertical 4 Clamp the butt router on the door and machine as normal If lock side prep is required remove the door push back the rollers and rest the door on the regular roll ers ...

Page 35: ... Powerfeed Wheels 4 11 Centering the Latch Drill in the Door 4 12 Aligning the Lock and Latch Drills 4 13 Adjustment of Drill Sensors Lock Drill 4 14 Adjustment of Drill Sensors Latch Drill 4 15 Latch Plate Mortise Centering 4 16 Latch Plate Mortise Depth 4 17 Main Bar 4 18 Jamb Rack Adjustment 4 19 Leveling the Router Carriage 4 20 Changing the Butt Router from 0 to 3 1 2 Deg 4 21 Butt Router Car...

Page 36: ...bed then you would remove 1 8 from the door at the high point of the bevel Should you experience problems in cutting a straight edge on your doors we urge you to proceed with caution in your efforts to correct the problem Ninety nine percent of all problems in this area arise from the cutterhead rather than the infeed bed outfeed bed or rollers If you have attempted to solve your problem and you a...

Page 37: ...on screws at least three turns 2 Loosen the adjusting nut set screw at least six turns 3 Reset the adjusting nut Turn clockwise for more torque or counterclockwise for less One valley at a time 4 Tighten the adjusting nut set screw in nearest spline notch Do not tighten set screw on threads of hub 5 Tighten the tension screws alternately and evenly until the heads bottom Do not use washers under h...

Page 38: ...s against a permanent reference or fence It doesn t matter how thick the door is the effec tive cutting height of the cutterhead remains constant assuming the diameter of the cutterhead and the set of the blades remain constant The relationship between the effective cutting height and the outfeed bed is extremely critical THEY MUST BE THE SAME HEIGHT or an uneven edge will result If you change the...

Page 39: ...aight edge door on the outfeed bed Pressing the door firmly against the machine roll it to your left until the left end of the door is over the cutterhead Using the pressure of the second powerfeed wheel to hold the door in place rotate the cutterhead backwards The cutter knives should touch the door but still turn freely If this condition does not exist raise or lower cutterhead until you achieve...

Page 40: ...OR DRIVE BELT The use of a dull Cutterhead will shorten the life of the mandrel bearings drive belt and the motor Your cutterhead motor is equipped with a motor base belt tension device Loosen the lock nuts securing the motor base to the rails not screws that secure rails to frame and turn the adjusting bolts clockwise to force the motor away from the cutterhead mandrel Be careful to keep the moto...

Page 41: ...8 16 hex bolt and raise or lower the idler pulley mounting block until there is about 1 deflection of the belt on the nearly vertical section of the belt near est the infeed end of the machine Be careful not to miss align the idler pulley as it is adjusted FIGURE 4 4 IDLER PULLEY Should the need arise to replace one or both powerfeed motors scribe a line around the base of the motor to be replaced...

Page 42: ...entire latch drill assembly toward you or away from you to achieve the dimension you arrived at in step 3 above The latch drill assembly can be moved in and out and the parallel to the frame can be changed by moving the top or bottom unequally to correct the angle drilled into the door 6 Tighten the hex bolts Under normal operating conditions the lock and latch drills will remain properly aligned ...

Page 43: ...43 SPECIAL ADJUSTMENTS FIGURE 4 5 ALIGNMENT WITH LOCK DRILL FAS TENERS 4 CENTERING ADJUSTMENT BOLTS FIGURE 4 5A LATCH BORE LOCK BORE ...

Page 44: ...move the sensor along the cylinder as needed Tighten down the screw when done FIGURE 4 6 HOME SENSOR LOCK BORE LIMIT SENSOR DOOR PULL SENSOR Under normal operating conditions the latch drill will remain properly adjusted for depth of cut Howev er should the need arise for adjustment the sensors on the cylinder will need to be moved as was the case with the lock drill As shown in figure 4 7 next pa...

Page 45: ...ame Be sure to retain the 1 16 gap between the template holder and the door when adjusting the mortise centering To center the latch mortise on the latch bore the air cylinder that activates the alignment cone can be ad justed on its mounting bracket Loosening the cylinder mounting bolts and shift the cylinder side to side not at an angle until the mortise is centered on the latch bore Tighten the...

Page 46: ...uld be 2 1 2 at each location If the dimension of the door to the main bar are equal but are not 2 1 2 the following procedure should be used 1 Calculate the difference of error from 2 1 2 as an example if the actual measurement is 2 7 16 the error would be 1 16 2 Move the door width scale pointer by the amount of the error up for a measurement less than 2 1 2 and down for a greater dimension unti...

Page 47: ...ve the correct angle To rotate the jamb rack loosen the jamb nut on the adjustment link and rotate the link By shortening the link the jamb is tilted toward the door angle decreases Lengthening the link tilts the jamb away from the door angle increases When making this adjustment be sure to check and adjust both ends of the jamb rack Angular Adjustment Adjustment Link Jamb Nut Framing Square Jamb ...

Page 48: ...ular to the face of the door before and after clamping it in place Before attempting to level the router carriage ascertain that the following two conditions exist The hinge edge of a square non tapered door is 2 1 2 above and parallel to the main bar figure 4 10 If this is not the case the main bar assembly needs to be adjusted see section 4 17 If the main bar is not correctly adjusted the mortis...

Page 49: ...e tram rollers and raise or lower the back plate until the jamb reference bars are resting flat on the door edge 3 Tighten the top center roller 4 Position and tighten the two lower rollers leaving 1 32 clearance between the roller and the tram rail This will permit the carriage to rock thus conforming to the door edge should the edge be slightly bowed 5 Adjust the felt wipers to effectively wipe ...

Page 50: ...nd 3 1 2 degree mortising the following procedure is recommended refer to fig 4 12 1 Unplug the butt router motor 2 Install the six jamb riser wedges 3 Lower the butt router assembly 4 Release both pivot lock pins by pulling the pin out and rotating it 90 degrees Push down on the butt router handle to cause the pivot blocks to move up in their slots While still holding the handle down rotate the l...

Page 51: ...into the carriage yourself you will need a press and two line reamers one 1 2 and one 5 8 To replace press or drive the old bush ing out FROM THE OPPOSITE END and press the new bushings in taking care not to damage them Once inserted line ream each pair of bushings to fit the matching slide rod Since most door shops do not normally have presses and line reamers we would suggest you contact the fac...

Page 52: ... oil based solvent electrical electronic contact cleaner Wipe dry DO NOT LUBRICATE 5 Inspect and clean weekly the two cam guides and rollers on the jamb rack These components are located on the backside of the jamb rack on opposite ends First blow the cavities clean then take a brush and clean any pitch left on the rollers and guides 5 2 CUTTERHEADS When the blades of the Cutterhead become dull or...

Page 53: ... is automatic but still needs to be checked daily to make sure it is dumping all the water The particulate air filter will require cleaning at intervals dependent on the quantity of impurities in your air supply The secondary filter coalescing is designed to remove very small impurities and oils from the air This filter must be replaced when the element appears discolored or dirty NOTE A DISCOLORE...

Page 54: ...D BUSHINGS With the exception of adding oil to the Lubricator no lubrication is required All bearings are pre lubri cated and sealed All bushings are self lubricating Nylatron or Oilite Note Bushing life will be lengthened by keeping slide rods clean Never use oil graphite or silicone spray on the bushings of any assembly of your machine to free it up Any foreign substance such as those above will...

Page 55: ...the latch drill return sensor the latch drill valve is turned off returning the latch drill to its home position Opening the clamps at any time during this cycle will immediately turn off the valve that is on returning the drills to their home position and resetting the cycle to the off position The flow control valve and controls the speed at which the cylinder retracts and extends meter when air...

Page 56: ...ler light IN 11 on when Fast or Slow held in Down position Width Slow Controller light IN 12 on when Slow held in either position Up Limit Controller light IN 13 on when Width Index is full Up Down Limit Controller light IN 14 on when Width Index is full Down Width Sensor Controller light IN 15 on when Width Index is on a Size Buzzer Controller light OUT 0 on when Buzzer is sounding Width Up Contr...

Page 57: ...Lock Drill 6 Latch Drill 7 Face Plate Lift 8 Face Plate Cone 9 Face Plate Motor Place Revision Label Here 0 Lock Drill On 1 Latch Drill On 2 Latch Drill Home 3 Latch Drill Return 4 Lock Drill Home 5 Lock Drill Return 6 Clamp Pedal 7 Cycle Pedal 8 Latch Router Start 9 Latch Router Stop Signal 10 Width Up 11 Width Down 12 Width Slow 13 Up Limit 14 Down Limit 15 Width Sensor PLC Inputs Software Revis...

Page 58: ...ROUTER STOP CONE DOOR CLAMP LOCK DRILL LATCH DRILL FACEPLATE ROUTER PLUNGE 6 4 WIDTH INDEX SPEED CONTROLLER The speed controller is located in the lower left corner of the main electrical panel This unit controls the width index motor speeds fast slow up and down This unit is not serviceable The speed controller is programmed at the factory with the right parameters for your machine If you should ...

Page 59: ...ING ACCELERATION 2 OC2 OVER CURRENT SHUT DOWN DURING CONSTANT SPEED 3 OC3 OVER CURRENT SHUTDOWN DURING DECELERATION 4 THM CONTROLLER OVERHEATING OR MOTOR OVERLOAD 5 OLT STALL PREVENTION 6 UV INSUFFICIENT VOLTAGE WARNING THIS ERROR IS SELF CORRECTING OPERATION WILL RETURN WHEN THE CORRECT VOLTAGE IS RESTORED IF A CODE IS DISPLAYED OTHER THAN THE ABOVE OR IF A CODE APPEARS REPEATEDLY CALL NORFIELD S...

Page 60: ...ed Contact factory for more infor mation Beveled edge shows snipe 2 3 inches from end of door Cutterhead is oversized Replace blades Cutterhead is too high Lower cutterhead mandrel Infeed bed in not parallel with outfeed bed Contact factory for more infor mation Main bar is stuck will not go up or down Obstruction in carriage assem blies Inspect entire carriage assem blies for screws or other fore...

Page 61: ... drill return sen sor Lock drill return sensor not functioning Repair or replace Lock drill feeds part through the door and motor stops running Motor overloaded Push re set button in electrical panel Feed rate is set too fast Adjust flow control valves on lock drill cylinder Lock drill completed its cycle but latch drill will not start Latch drill cycle is turned Off on control panel Turn switch t...

Page 62: ...lide shafts as described in preventive maintenance Air pressure too low Air pressure must be maintained at 90 100 PSI Latch drill travel switch set in Short position on operator panel Set switch to long position Latch drill not centered in door Clamp back up block is the wrong thickness Use good quality 3 4 particle board for making back up blocks Missing or worn drill clamp pads Replace clamp pad...

Page 63: ...er in the door than in the jamb Jamb is not up against the bot tom of the router carriage Raise the jamb rack Router carriage is not level when mortising See adjustments in Section 4 19 Edge of door and jamb rack are not parallel Make sure the door edge is 2 1 2 above the main bar at both ends of the door Faceplate mortise is not centered Back up block is wrong thickness Use good quality 3 4 parti...

Page 64: ... have an insert type bit Latch and lock motors start but will not run or run intermittently Latch Lock stop pushbutton not making contact Replace contact block Switch contacts of motor are not making contact Repair or replace contacts No electrical functions operating at controller E stop button is depressed Check E stop Defective E stop contact block Replace contact block Circuit breaker tripped ...

Page 65: ...plate router motor will not run Faceplate router switch is not making contact Repair or replace Faceplate router is defective Repair or replace Circuit breaker tripped Reset or replace Defective relay Reset or replace Butt router automatic start will not run Mercury switch not making contact Readjust or replace mercury switch Switch in router head is not mak ing contact Replace switch in router he...

Page 66: ...replacing free of charge F O B Chico California any parts proved to be defective within the period of the warranty Norfield will not be responsible for transportation charges or consequential damages Norfield will not in any case or under any circumstances be liable or responsible for any injuries to per sons or property suffered as a result of the use or operation of the machine or losses or cost...

Page 67: ...ccessories Our team of Customer Care Representatives is available to support you If you need to contact the Norfield Service department please have the following information available Serial Number of the machine Model of the Machine Date of purchase or date that the machine was installed Voltage of the machine A description of the problem and in what part of the machine the problem is occurring F...

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