Norfield 4800XY User manual

OPERATOR MANUAL
Release: 1
4800XY
Door Lite Machine
Eective S/N: XY-0001 Document Number: 17-357

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First Release: September 2019

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Noreld
422 Oerson Dr
Chico, Ca. 95928
Technical Support: [phone] - Parts: [phone]
Serial No: _____________________
Date Sold: _____________________
Noreld is the name that represents Quality, Reliability, Support, Innovation and True
Customer Service. We have been dedicated to providing quality products and excellent
customer service for more than 40 years.
Noreld has earned a reputation in the pre
hanging industry for seing standards for reliable machinery, full technical support, ma-
chine parts, full line industrial woodworking tools and supplies and a team of customer
care representatives to support you! Our factory-trained technical personnel are ready to
assist you on the telephone or in your shop.

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TABLE OF CONTENTS
Safety ...........................................................................................................6
Lockout Procedures ...................................................................................9
Operation
Quick Start guide ......................................................................................11
Controls ......................................................................................................12
Operation....................................................................................................17
Adjustments
Flow control ...............................................................................................19
Door stops ..................................................................................................20
X & Y stops .................................................................................................21
Drill section ................................................................................................25
Oscillating quill .........................................................................................27
Maintenance Checklist ...........................................................................28
Trouble Shooting .......................................................................................29
Warranty & Parts Replacement Policy ...................................................35
Contact & Order Information ..................................................................36

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6
SAFETY
Safety considerations are an important element
of machine installation and operation. Actively
maintaining a safety mindset about yourself and
others while working around or on the
equipment is of primary importance. Operators and
maintenance personnel should refer to the safety informa-
tion on the following pages to familiarize themselves with
warning labels and practices providing for safe operation
and servicing of this machine.
Danger indicates an imminently hazardous situation, which if
not avoided WILL result in death or serious injury.
Warning indicates a potentially hazardous situation 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 M AY result in
property damage but not personal injury.
Notice indicates important information that if not followed
may CAUSE damage to the equipment.
Mandatory Action conveys an action step that should be
taken to avoid the hazard.
SAFETY

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SAFETY
Do not operate this machine unless all guards are in place and working cor-
rectly. If any guards or hazard labels are missing or damaged call Noreld’s
Service Department immediately and request a replacement at [phone].
Read and understand the operator’s manual before using this machine. Fail-
ure to follow proper operating instructions could result in death or serious
injury.
This machine, when in operation, produces wood chips and dust. The op-
erator and all persons in the work area MUST wear approved eye protection
with permanently aached, rigid plastic side shields. These safety glasses
must conform to ANSI Z87.1 standards and will have “Z87” printed on the
lens.
This machine, when in operation, produces a noise level greater than 85dB.
The operator and all persons in the work area MUST wear approved hearing
protection. OSHA has 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 personal
dusk mask MUST be used when operating this equipment.
This machine has moving parts that loose clothing and long hair can become
entangled in. Take care not to become caught between the work material and
the feed mechanisms or any other moving components.
Before beginning any service repairs, general maintenance, or adjustments
you MUST follow proper Lockout Tag-Out procedures. OSHA regulation
1910.147 establishes a minimal lockout tag-out procedure to assist employers
in the development of their own procedures.
Only trained personnel that have read and understand the operator’s manual
and all the safety precautions may operate this machine.

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Inspect the machine at the beginning and end of each shift for damaged or
cracked components such as, but not limited to, saw blades, router bits, drill
bits, and boring bits.
Never leave this machine unaended while it is in operation. Make sure that
all electrical and air is in the o position when the machine is not in use or is
unaended and that any cuing blades have come to a complete stop.
Do not aempt to clean material from this machine until all the cuing blades
have come to a complete stop. Even when the machine has been turned to
the “o” 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 injury.
If you have any questions regarding the correct operation of the machine
and safety procedures in this manual call the Noreld Service Department at
(800)-824-6242
SAFETY

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LOCKOUT PROCEDURES
All employees will comply with these procedures. All equipment and/or circuits will be
locked out to protect against accidental or inadvertent operation when such operation of
the equipment and/or circuits could cause injury to personnel. Do not aempt to operate
any switch, valve, or other energy isolating device bearing a lock.
Lockout Responsibility
The primary responsibility for the proper lockout of equipment and /or circuits on a
maintenance or repair project belongs to the project Supervisor and/or Foreman. How-
ever, this does not alleviate any sub-contracted maintenance or repair personnel from
insuring that proper lockout/tagout procedures are followed at all times. The Supervi-
sor and/or Foreman will insure that each employee is properly instructed in the safety
signicance of lockout procedures.
Preparation for Lock-Out of Circuits and Equipment
In the following steps, when more than one individual is involved with the project and
required to lock out the equipment and/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 for carrying out all steps of the lockout procedure. That individual will inform
the work crew when it is safe to work on the equipment and/or circuits. Additionally,
the designated individual will not remove a crew lock until it has been veried that ALL
individuals are clear.
1. Notify all aected employees and customers that a lockout is required and the reason
for it.
2. If the equipment is in operation, after obtaining approval, shut it down by the normal
stopping procedures.
The following is an example of the minimum requirements for a lockout/tagout
procedure. Noreld strongly recommends that your company establish its own wrien
procedure. OSHA Regulation 1910.147 establishes a minimal lockout/tagout procedure
to assist employers in the development of their own Lockout Procedures
LOCKOUT PROCEDURES

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3. Operate the switch, valve or other energy isolating devices so that all energy sources
(electrical, mechanical, pneumatic, hydraulic, etc.) are disconnected or isolated from
the equipment and/or circuits. Stored energy, such as that in capacitors, springs,
elevated machine members, rotating ywheels, hydraulic systems, and air/gas,
steam or water pressure, etc., must also be dissipated or restrained by methods such
as grounding, repositioning, blocking, bleeding down, etc.
4. All aected employees are then required to lockout the energy devices with their
individual lock.
5. After insuring that no personnel are exposed and as a check on having disconnected
the energy sources, operate the push buon 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 position.
The equipment and/or circuits are now locked out.
Restoring Equipment and/or Circuits to Service
1. When the job is complete and the equipment or circuits are ready for testing or nor-
mal service, check the equipment and/or circuits to insure that no one is exposed.
2. When the equipment and/or circuits are clear, remove all locks. The energy isolating
devices may be operated to restore energy to the equipment and or circuits.
LOCKOUT PROCEDURES

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4800XY QUICK START GUIDE
1. Adjust the width index to be slightly larger than the door to be processed.
2. Insert the door from the side with the head toward the door stop and the lock side
away from the operator’s side of the machine.
3. Push the door against the door stop and clamp the door.
4. Turn on or o the oscillating quill aachment as needed for the door being cut.
Lite Cutout:
5. Move the machining head to a position near one of the X or Y stops. Clamp both the
X and Y axis.
6. Start the machining head motor and plunge the bit through the door.
7. Unclamp one axis and push the head to the stop collar and re-clamp that axis.
8. Unclamp the other axis and push the head toward another stop collar.
9. Repeat this process until you have gone all the way around. Always travel in a
clockwise direction.
Lock Prep:
10. Extend the lock template and position the machining head over the template.
11. Lower the template follower into the template, lock both the X and the Y axis, start
the machining head motor, and plunge the bit.
12. Unlock both the X and the Y axis and push the template follower around the lock
template. Always travel in a clockwise direction.
13. Raise the bit, stop the motor, raise the template follower, and retract the lock tem-
plate.
14. Start the latch drill motor and push the cycle start buon.
15. When the cycle is complete, if dead bolt is needed, move the door to the dead bolt
stop and repeat steps 10 through 14.
OPERATIONS

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OPERATIONS
CONTROLS 4800XY BASIC
Control Power:
The control power switch is used to turn on and o the power to the controller and
the controls. This is not a service disconnect. To service the machine turn o and
lock out the disconnect switch on the main electrical box.
Machining Head:
This control starts and stops the door lite cutout motor.
Template Guide Plunge:
Pressing this buon will alternately raise and lower the template guide. The tem-
plate guide is used to follow a template that is inserted above the door.
Door Lite Bit Plunge:
Pressing this buon will alternately raise and lower the door lite bit. Start the ma-
chine head motor before plunging the door lite bit.
Basic Control Panel

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OPERATIONS
Width IN:
Press this buon to move the width index “IN” for a narrower door.
Width OUT:
Press this buon to move the width index “OUT” for a wider door.
Door Clamp:
Pressing this buon will alternately clamp and unclamp the door.
Template Clamp:
Pressing this buon will alternately clamp and unclamp the template. The template
clamp is used to secure a template that is inserted above the door.
X & Y Axis Locks:
The X and Y Axis lock switches are located to the right of the control panel.
The X-axis is to the operator left and right. The Y-axis is toward and away from the
operator.
Locking the X axis will allow the cuer to move in the Y direction only.
Locking the Y axis will allow the cuer to move in the X direction only.

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OPERATIONS
X Travel Stop:
The X travel stop switch raises and lowers the X travel stop. Push the switch down
to lower the stop and up to raise the stop. This allows the operator to lower the stop
to contact the collars needed for the lite being cut and raise it to bypass the collars
not needed.
4800XY WITH EDGE PREP OPTION
Control Power:
The control power switch is used to turn on and o the power to the controller and
the controls. This is not a service disconnect. To service the machine turn o and
lock out the disconnect switch on the main electrical box.
Machining Head:
This control starts and stops the door lite cutout motor.

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OPERATIONS
Template Guide Plunge:
Pressing this buon will alternately raise and lower the template guide. The tem-
plate guide is used to follow a template that is inserted above the door.
Door Lite Bit Plunge:
Pressing this buon will alternately raise and lower the door lite bit. Start the ma-
chine head motor before plunging the door lite bit.
Width IN:
Press this buon to move the width index “IN” for a narrower door.
Width OUT:
Press this buon to move the width index “OUT” for a wider door.
Door Clamp:
Pressing this buon will alternately clamp and unclamp the door.
Template Clamp:
Pressing this buon will alternately clamp and unclamp the template. The template
clamp is used to secure a template that is inserted above the door.
Latch Drill:
This control starts and stops the Latch Drill motor.
Edge Prep Mode:
This switch is used to select the function of the edge prep cycle.
• When the switch is in the Latch position only the latch hole will be drilled
when the Edge Prep Cycle Start is pressed.
• When the switch is in the Faceplate position only the faceplate mortise will be
cut when the Edge Prep Cycle Start is pressed.
• When the switch is in the both position the Latch drill and the faceplate mor-
tise will both be cut when the Edge Prep Cycle Start is pressed.
Edge Prep Cycle Start:
This buon starts the edge prep cycle. Please see Edge Prep Mode above to deter-
mine the function of the edge prep cycle.
X & Y Axis Locks:
The X and Y Axis lock switches are located to the right of the control panel.
The X-axis is to the operator left and right. The Y-axis is toward and away from the
operator.
Locking the X axis will allow the cuer to move in the Y direction only.
Locking the Y axis will allow the cuer to move in the X direction only.

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OPERATIONS
X Travel Stop:
The X travel stop switch raises and lowers the X travel stop. Push the switch down
to lower the stop and up to raise the stop. This allows the operator to lower the stop
to contact the collars needed for the lite being cut and raise it to bypass the collars
not needed.
Lock Template Extend - Retract:
This switch extends and retracts the lock bore template. Push the switch up to ex-
tend the lock template. This template is used to cut a lock bore through the face of
the door.
Push the switch down to retract the lock template.
NOTE: The lock template must be retracted to do a face plate mortise.

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OPERATIONS
4800 XY OPERATING PROCEDURES
POSITION AND CLAMPING THE DOOR
1. SELECT THE DOOR TO BE PROCESSED:
Before you begin you need to know the height and width of the door. Also the
size and shape of the lite to be cut.
2. ADJUST THE WIDTH INDEX:
Move the width index to a size about 1 or 2 inches larger than the door. This will
make it possible to get the door into the machine. The width will move in and
“crowd” the door as part of the door clamping process. The width scale is located
to the operators left.
3. INSERT THE DOOR.
The door is inserted, from the side of the machine, with the head toward the door
stop and the lock side away from the operator’s side of the machine. The door
stops may be installed at either end of the machine.
4. PUSH THE DOOR AGAINST THE DOOR STOP AND CLAMP THE DOOR:
The head of the door should always be against a door stop. Knowing the door
size and the process being done to the door will determine the door stop to be
used.
Hold the door against the door stop and press the door clamp buon. The width
index will crowd the door and clamp it up.

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OPERATIONS
LITE CUTOUT, RECTANGLE ONLY:
5. INSTALL THE X & Y STOP BARS:
There could be multiple stop bars with the machine. Select the bars that are setup
for the lite needed in this door.
6. CLAMP BOTH THE X AND Y AXIS.
Clamping both the X and the Y axes will ensure that the head will not move when
the bit is plunged through the door. Allowing the bit to move while plunging could
result in damage to the product or the machine. It could also result in personal inju-
ry.
7. PLUNGE THE BIT THROUGH THE DOOR:
Start the machining head motor, move the head close to one of the stop collars and
press the Door Lite Bit Plunge buon. As the bit plunges through the lower skin of
the door it will cause a dimple. If you plunge away from a stop you will remove the
dimple when you nish the lite.
8. CUTOUT THE LITE:
Unclamp one axis and push the head to the closest stop and re-clamp that axis.
Unclamp the other axis and push the head toward another stop collar.
Repeat this process until you have gone all the way around. Always travel in a
clockwise direction.
OSCILLATING QUILL
The oscillating quill aachment causes the cuer to move up and down a small
amount at the boom of the plunge. When cuing steel doors this allows more of
the cuing edge to be used to cut the steel skin.
On the left side of the machining head there is a bracket with two sensors. There is
also an L shaped tab. The tab can be rotated to activate the sensors.
To use the oscillator position the tab so the quill will go all the way down and when
it comes back up the cuing edge of the cuer does not go above the boom skin of
the door.
To turn the oscillator o rotate the tab so it does not activate the sensors.
LOCK PREP:
9. Extend the lock template and position the machining head over the template.
10. Lower the template follower into the template, lock both the X and the Y axis,
start the machining head motor, and plunge the bit.
11. Unlock both the X and the Y axis and push the template follower around the lock
template. Always travel in a clockwise direction.
12. Raise the bit, stop the motor, raise the template follower, and retract the lock tem-
plate.
13. Start the latch drill motor and push the cycle start buon.
14. When the cycle is complete, if dead bolt is needed, move the door to the dead bolt
stop and repeat steps 9 through 13.

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OPERATIONS
LITE CUTOUT USING A TEMPLATE
1. CLAMP A DOOR INTO THE MACHINE
Complete steps 1 through 4 from above.
2. SLIDE THE TEMPLATE INTO THE TEMPLATE HOLDER.
Select the appropriate template and slide it into the template holder from the
end. Align it to the door.
3. CLAMP THE TEMPLATE
Press the template clamp buon, the buon should light up indicating that the
template is clamped.
4. CLAMP BOTH THE X AND Y AXIS.
Clamping both the X and the Y axes will ensure that the head will not move
when the bit is plunged through the door. Allowing the bit to move while plung-
ing could result in damage to the product or the machine. It could also result in
personal injury
5. PLUNGE THE BIT THROUGH THE DOOR:
Start the machining head motor, move the head close to one side of the template
and press the Door Lite Bit Plunge buon. As the bit plunges through the lower
skin of the door it will cause a dimple. If you plunge away from the edge you
will remove the dimple when you nish the lite.
FLOW CONTROL ADJUSTMENT
Most of the cylinders on Noreld machines have a ow control on each end. The
ow controls are used to control the speed of the cylinder. Flow controls control
the speed of the exhaust air.
Therefore the ow control that is in the direction of travel is the one controlling
the speed.

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DOOR STOP ADJUSTMENT
The 4800 comes with one door stop assembly and four door stops. The door stop
assembly can be mounted at either end of the machine, so the head of the door
can be to the operator’s right or the left. Deciding which end to mount the stop
assembly could help to optimize material ow within your shop layout.
The photo above shows the stop assembly mounted to the operator’s right.
Each of the door stops has a clamp collar to the right of the stop and to the
left of the stop there is a spring washer and a clamp collar.