Martin Yale PL215 Paper Cutter
Martin Yale PL215 Paper Cutter
Error 11 Instructions
Provided By
http://www.MyBinding.com
http://www.MyBindingBlog.com
PL215/PL265 Error 11 Instructions An ERROR CODE 11, subreference 19 means “missed or slowed encoder pulses.” What to do: 1. 2. 3.
Go to Diagnostic test 3 by holding down ‘setup’ key while powering up. You can release the ‘setup’ button once machine is on. Push ‘3’ key for TEST 3. Press ‘mode’ key until screen reads “stepper motor only,” and verify that you can move the backguage 3 inches in both directions with the arrow keys. Press the mode key until it says “AC motor only” and repeat, if both motors energize and drive the backguage normally, proceed to Diagnostic test 9, by pressing ‘UNDO’ to get to the diagnostics prompt, and then pressing ‘9’.
If both motors do not drive the back-guage normally, listen for any sounds of mechanical bind-up. This could indicate a need to lubricate, or mechanical damage that needs to be pinpointed. If both motors cannot individually move the backguage, the next step is to determine which motor is having difficulty. Because of the size difference in the two motors, the stepper motor tends to be the common one with an issue. If the AC motor is having trouble, then it is either going to be a no power situation or there is going to be a mechanical issue in the drive system for the backguage. Main board connections to be checked would be JFOR, JREV and JACL. These are the forward, reverse and voltage connections for the AC motor. If JFOR and JREV were reversed, the back-guage would move backwards when the forward key was pressed and would move forward when the reverse key was pressed (common field mistake). BEFORE isolating the issue with the stepper motor, check the fuse (F1) on the main logic board. *NOTE: if the stepper motor is not functioning, or the backguage is at the rear of the deck and has no room to move backwards, TEST 9 will not operate (alignment error). Reasons for the stepper motor to energize but not move. 1. 2. 3. 4.
Mechanical damage/lubrication in regard to backguage worm screw. Excessive belt tension on stepper motor (belt should be loose). A bad or unclean connection at JSTEP connection on the main logic board (remove and reseat). Defective stepper driver chip (see section on driver chip isolation).
If everything seems to be normal and the machine is oiled, belt tension for the stepper motor is nominal (loose), and the stepper motor has power but still does not move: unplug the 4-wire connection (at JSTEP) and take a resistance reading for the windings in the motor on the two left connection points, and then, the two right: *NOTE: Pin 1 can be either end. Ø Pins 1+2 = approximately 1.7-2.1 OHMS
I
Ø Pins 3+4 = approximately 1.7-2.1 OHMS OHMS readings for both windings should be approximately equal. Any difference in readings could potentially indicate a motor with a failed or failing winding. This encompasses the majority of issues seen in the system, and by this point, you should have a functional stepper motor. If you do not, call technical support at Martin Yale Industries, Inc. at 219-563-0641.
Backgauge Pulley
Dual Pulley
AC Motor
Stepper Motor
Encoder Sensor
DIAGNOSTIC TESTS 7 & 9 TEST 7: Initiating test 7 will be a test of the homing system, and the machine’s ability to home and move the backguage to various positions. Any failure here will likely be concerning the encoder or home flag system. When the test number (7) is pressed the backguage will move on its own, no interaction is necessary on keyboard. If this test fails the machine will inform you with an alignment error. TEST 9: *NOTE: When starting test 9, the backguage should be 2-3 inches away from the blade. When you choose test 9, it will read “automeasure-depress speed key”. At this point the stepper motor will energize and you should see (D1: xx D2: xx PH: xx) these are the readings for the encoder system and should all be .50 +/- .06 (.44-. 56). There should not be a great deal of fluctuation in the readings .02% on each one would be nominal. Any more than that might indicate bent teeth on the encoder disk, or possibly a loose encoder sensor board.
II
READINGS D1 & D2 are potentiometer adjustments on the encoder PC board. They are two orange plastic phillips heads. D1 & D2 readings can be adjusted by turning the screws. It is doubtful that they would need to be, unless the encoder sensor board has been replaced, or screws were moved. If adjusting these you must be careful to not move the board itself with the screwdriver. The most likely scenario would be the PH adjustment or, the physical positioning of the sensor itself, would be out of position. Another possibility would be that lubricant got into the sensor during service of the machine. If an unexplainable alignment error occurs, the first thing to do is verify that the machine is sending a binary code to the main board from the encoder sensor. Stepper Driver Chip (Under heat sink)
EPROM JENC
JSTEP
JOPSW
JFOR JREV JACL
VERIFYING ACTIVITY In order to verify a return signal form the encoder, we have to plug it into the home-flag sensor connection. You have to unplug JENC (encoder) and JOPSW (home flag) and then plug JENC into JOPSW. Once this is done, go to diagnostic test 4. (JOPSW can be left unattached). In test 4 you will see a reading for ‘HOME’ it will either be a ‘0’ or a ‘1’. As you slowly rotate the pulley for the stepper motor, you should see the reading alternate between ‘0’ and ‘1’. If this occurs it is functioning and would need to be realigned if one of the following things is occurring:
III
1. 2. 3.
When test 9 is ran, the backguage does move, but you receive an alignment error. You do get readings, but are not within specification. You get normal readings but with a substantial fluctuation of the numbers (bent teeth, loose board).
NOTE: If you press speed, and the backguage runs, but the screen does not change, suspect a bad connection at JENC on main board, or at the encoder sensor board. Once the test is completed, do not forget to replace your connections back to their original format. (DO NOT RUN TEST 9 WITH CONNECTION REVERSED). PHASE-ALIGNMENT ON ENCODER DISK SENSOR BOARD In order to restore phase-alignment of the encoder disk sensor board, the board will need to be physically tweaked (by rocking it with your thumb and forefinger). The two screws that hold the board in place should be tight, which gives the technician an idea of how precise an adjustment it is. Since diagnostic test 9 has to be ran to test the phase, and the pulley configuration is in front of the encoder system, it would be necessary to tweak the board and then run diagnostic test 9, and repeat as necessary. The initial goal is to get the best phase reading possible. It is feasible that the sensor board could be attended with the test energized, but it is not advised. On some occasions it is necessary to loosen the two screws that hold the sensor on the frame. If necessary, loosen one screw completely, and the other only partially (close to snug). That way when positioning is reached the board can be let go long enough to tighten the screws without the board moving. Remember, at this point we only want to get a reading, once received, fine positioning can be done for the best reading possible. There is a mathematical relationship between D1, D2 and PHASE. What this means is that by adjusting any one of the three, the other two will be affected. Usually once you have got the best phase reading possible adjusting D1and D2 will allow all three to come within specification (.50 +/- .06). NOTE: Average field alignment time is 25 min. (there is only about a .003” window from which the encoder sensor board can accurately see the encoder disk). When phase alignment is completed, go to diagnostic test 9 and press the SPEED key (backguage must be at front of cutting deck for test to run). At this point the backguage will energize. Once the backguage is moving, press the 8 key. There should be approximately a 15-second wait and then the machine should prompt ‘OK’.
Connection Pins
Sensor Gate
D1 & D2
Error 11 Instructions
Provided By
http://www.MyBinding.com
http://www.MyBindingBlog.com
PL215/PL265 Error 11 Instructions An ERROR CODE 11, subreference 19 means “missed or slowed encoder pulses.” What to do: 1. 2. 3.
Go to Diagnostic test 3 by holding down ‘setup’ key while powering up. You can release the ‘setup’ button once machine is on. Push ‘3’ key for TEST 3. Press ‘mode’ key until screen reads “stepper motor only,” and verify that you can move the backguage 3 inches in both directions with the arrow keys. Press the mode key until it says “AC motor only” and repeat, if both motors energize and drive the backguage normally, proceed to Diagnostic test 9, by pressing ‘UNDO’ to get to the diagnostics prompt, and then pressing ‘9’.
If both motors do not drive the back-guage normally, listen for any sounds of mechanical bind-up. This could indicate a need to lubricate, or mechanical damage that needs to be pinpointed. If both motors cannot individually move the backguage, the next step is to determine which motor is having difficulty. Because of the size difference in the two motors, the stepper motor tends to be the common one with an issue. If the AC motor is having trouble, then it is either going to be a no power situation or there is going to be a mechanical issue in the drive system for the backguage. Main board connections to be checked would be JFOR, JREV and JACL. These are the forward, reverse and voltage connections for the AC motor. If JFOR and JREV were reversed, the back-guage would move backwards when the forward key was pressed and would move forward when the reverse key was pressed (common field mistake). BEFORE isolating the issue with the stepper motor, check the fuse (F1) on the main logic board. *NOTE: if the stepper motor is not functioning, or the backguage is at the rear of the deck and has no room to move backwards, TEST 9 will not operate (alignment error). Reasons for the stepper motor to energize but not move. 1. 2. 3. 4.
Mechanical damage/lubrication in regard to backguage worm screw. Excessive belt tension on stepper motor (belt should be loose). A bad or unclean connection at JSTEP connection on the main logic board (remove and reseat). Defective stepper driver chip (see section on driver chip isolation).
If everything seems to be normal and the machine is oiled, belt tension for the stepper motor is nominal (loose), and the stepper motor has power but still does not move: unplug the 4-wire connection (at JSTEP) and take a resistance reading for the windings in the motor on the two left connection points, and then, the two right: *NOTE: Pin 1 can be either end. Ø Pins 1+2 = approximately 1.7-2.1 OHMS
I
Ø Pins 3+4 = approximately 1.7-2.1 OHMS OHMS readings for both windings should be approximately equal. Any difference in readings could potentially indicate a motor with a failed or failing winding. This encompasses the majority of issues seen in the system, and by this point, you should have a functional stepper motor. If you do not, call technical support at Martin Yale Industries, Inc. at 219-563-0641.
Backgauge Pulley
Dual Pulley
AC Motor
Stepper Motor
Encoder Sensor
DIAGNOSTIC TESTS 7 & 9 TEST 7: Initiating test 7 will be a test of the homing system, and the machine’s ability to home and move the backguage to various positions. Any failure here will likely be concerning the encoder or home flag system. When the test number (7) is pressed the backguage will move on its own, no interaction is necessary on keyboard. If this test fails the machine will inform you with an alignment error. TEST 9: *NOTE: When starting test 9, the backguage should be 2-3 inches away from the blade. When you choose test 9, it will read “automeasure-depress speed key”. At this point the stepper motor will energize and you should see (D1: xx D2: xx PH: xx) these are the readings for the encoder system and should all be .50 +/- .06 (.44-. 56). There should not be a great deal of fluctuation in the readings .02% on each one would be nominal. Any more than that might indicate bent teeth on the encoder disk, or possibly a loose encoder sensor board.
II
READINGS D1 & D2 are potentiometer adjustments on the encoder PC board. They are two orange plastic phillips heads. D1 & D2 readings can be adjusted by turning the screws. It is doubtful that they would need to be, unless the encoder sensor board has been replaced, or screws were moved. If adjusting these you must be careful to not move the board itself with the screwdriver. The most likely scenario would be the PH adjustment or, the physical positioning of the sensor itself, would be out of position. Another possibility would be that lubricant got into the sensor during service of the machine. If an unexplainable alignment error occurs, the first thing to do is verify that the machine is sending a binary code to the main board from the encoder sensor. Stepper Driver Chip (Under heat sink)
EPROM JENC
JSTEP
JOPSW
JFOR JREV JACL
VERIFYING ACTIVITY In order to verify a return signal form the encoder, we have to plug it into the home-flag sensor connection. You have to unplug JENC (encoder) and JOPSW (home flag) and then plug JENC into JOPSW. Once this is done, go to diagnostic test 4. (JOPSW can be left unattached). In test 4 you will see a reading for ‘HOME’ it will either be a ‘0’ or a ‘1’. As you slowly rotate the pulley for the stepper motor, you should see the reading alternate between ‘0’ and ‘1’. If this occurs it is functioning and would need to be realigned if one of the following things is occurring:
III
1. 2. 3.
When test 9 is ran, the backguage does move, but you receive an alignment error. You do get readings, but are not within specification. You get normal readings but with a substantial fluctuation of the numbers (bent teeth, loose board).
NOTE: If you press speed, and the backguage runs, but the screen does not change, suspect a bad connection at JENC on main board, or at the encoder sensor board. Once the test is completed, do not forget to replace your connections back to their original format. (DO NOT RUN TEST 9 WITH CONNECTION REVERSED). PHASE-ALIGNMENT ON ENCODER DISK SENSOR BOARD In order to restore phase-alignment of the encoder disk sensor board, the board will need to be physically tweaked (by rocking it with your thumb and forefinger). The two screws that hold the board in place should be tight, which gives the technician an idea of how precise an adjustment it is. Since diagnostic test 9 has to be ran to test the phase, and the pulley configuration is in front of the encoder system, it would be necessary to tweak the board and then run diagnostic test 9, and repeat as necessary. The initial goal is to get the best phase reading possible. It is feasible that the sensor board could be attended with the test energized, but it is not advised. On some occasions it is necessary to loosen the two screws that hold the sensor on the frame. If necessary, loosen one screw completely, and the other only partially (close to snug). That way when positioning is reached the board can be let go long enough to tighten the screws without the board moving. Remember, at this point we only want to get a reading, once received, fine positioning can be done for the best reading possible. There is a mathematical relationship between D1, D2 and PHASE. What this means is that by adjusting any one of the three, the other two will be affected. Usually once you have got the best phase reading possible adjusting D1and D2 will allow all three to come within specification (.50 +/- .06). NOTE: Average field alignment time is 25 min. (there is only about a .003” window from which the encoder sensor board can accurately see the encoder disk). When phase alignment is completed, go to diagnostic test 9 and press the SPEED key (backguage must be at front of cutting deck for test to run). At this point the backguage will energize. Once the backguage is moving, press the 8 key. There should be approximately a 15-second wait and then the machine should prompt ‘OK’.
Connection Pins
Sensor Gate
D1 & D2
