On the under side of the head of there are two compression rollers. The rollers have switches that are used to detect that a board has been loaded and to assist in measuring the length of a board.
The "Possible Board Removal" error occurs when the wrong roller drops first. For example, if the board is being moved towards the back of the machine, then we expect the front roller to drop first. In this example, if the back roller drops first we throw the "Possible Board Removal" error.
Possible causes:
1) Board feature that causes a roller to drop, when is is not at the end of the board. If you have such a feature, then you probably need to create a jig for your workpiece.
2) If the board has come out from underneath both rollers, then it is likely that the roller that should have released first is stuck. Compress the offending roller with your hand and you should hear a click both when it compresses and releases. If you don't hear the clicks, then check that sawdust hasn't become clogged in the switch. You can also use item 7 under the options menu to ensure that the machine is sensing the roller state changes.
3) Low head compression. Ensure that you crank the head all the way down onto the board until the clutch slips. You may also try adding a little downward pressure on the head as you crank it down. If you have to press down or cannot get a board loaded indication, please call us so that we can resolve the issue.
Since you say the board stops in the middle and that it happens on many different pieces, it sounds like you may be having problems with the head compression. Try pushing down on the head as described to see if it helps. This could at least get you up and running, but either way give us a call so that we can provide a more appropriate resolution.
Chris Morlier
CarveWright