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1. Backing up the Computer on page 3 3 e Lubricate linear bearings and chrome shafts with silicone KVAL 979 2 Operation Service Manual 4 3 Lubrication Requirements AL Lubrication Requirements This section describes the parts of the machine that require periodic lubrication and specifies the lubricants In addition it explains how to maintain the lubrication systems on the machine Linear Bearings Flange Bearing and Pillow Blocks If the bearing is equipped with a grease fitting Zerk Fitting t should receive Gram one pump from grease gun of Dura Lith Grease K VAL P N Lube EP 2 every 250 hours of operation Note Bearings without grease fittings have been pre lubricated at the factory and do not require further lubrication Zerk Fittings Zerk Fitting Location Depends on Position of Slide FIGURE 4 12 Zerk Fittings 4 4 KVAL 979 2 Operation Service Manual Lubrication Requirements Gear Motor Lubrication Requirements Oil change is recommended after 2000 operation hours of operation Use AGMA 8 gear lube or MOBILUBE HD 80 W 90 or equivalent Ball Screws All ball screws should be lubricated Dura Lith Grease K VAL P N Lube EP 2 for every 80 hours of operation At each lubrication grease should be pumped into the fitting until clean grease comes out around the ball screw Ball screw lubrication points End Bearing End Bearing Ball Screw Ball Nut FIG
2. Q designation represents an output from the PLC Switch Feed Dog Retracted 9 Switch Feed Dog Extended Left Head Switches 45 degrees Saw Retracted Saw Extended Kerf Saw Retracted Kerf Saw Extended Sensor Left Board Straight Sensor Right Board Straight Sensor Open Limit Right Head Switches 45 degrees Saw Retracted Saw Extended Kerf Saw Retracted Kerf Saw Extended Sensor Home Sensor Close Limit FIGURE5 21 Location of Sensors Top View 979 2 5 8 KVAL 979 2 Operation Service Manual WAL i Troubleshooting Electrical Problems Troubleshooting Electrical Problems Refer to Air and Electrical Schematics provided with delivery of the machine Schematics are located in the Electrical Panel If copies are unavailable contact the KVAL Service Department Have model number and serial number of machine readily available NOTE Warning The following checks require the electrical panel to be A energized These troubleshooting checks must be per formed by a Qualified Electrical Technician The electrical component systems are designed to expedite the troubleshooting process and mini mize down time In general component systems have the input or feed functions at the top Output or load functions are positioned at the bottom Most two voltage electrical panels are designed with the LOW VOLTAGES on the LEFT and the HIGH VOLTAGES on the RIGHT The majority of the syste
3. 5 If no power on the output side and there is power going into the top of the Control Transformer replace the Control Transformer 6 If there is power at the Control Transformer check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip 5 12 KVAL 979 2 Operation Service Manual Ca Troubleshooting Electrical Problems Overload Relay Light OFF 1 Check Motor Overload Circuits 2 With power on check the trip indicator LED on the overload If indicator is orange press the Reset Button to reset the overload circuit Retest the Machine Trip Indicator Contactors Factory Set Current Overload Rating Adjust Relays se Reset Button Fac tory set on the H Setting z E Stop Light OFF Check to see the f any E Stop buttons are pulled out NOTE Location and quantity of E Stop buttons varies depending on customer need Typical locations for E Stop buttons are near the Rear Access Gate and near the Tool Changer Access Gate D Stop Light OFF Check for 110 VAC between 2 and 4 If there is voltage press the Start button If no voltage check the Stop button to make sure it is all the way out and not stuck in then check the contact to make sure it 1s closed If still no voltage check the wiring KVAL 979 2 Operation Service Manual 5 13 Troubleshooting Electrical Problems B Start Light
4. Innovation Quality amp Honesty 979 2 Miter Trim Saw System Operation and Service Manual Published 2 23 15 Proprietary Notice This Manual is confidential and contains proprietary information and intellectual property of KVAL Inc and is to be used solely by Customer as an operating manual for KVAL Inc machines Neither this Manual nor any of the information contained herein may be reproduced or disclosed under any circumstances without the express written permission of KVAL Inc For authorization to copy this information please call Kval Customer Support at 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 Manual Part Number 146 OPSRV_979 2 V1 The 979 2 Miter Trim Saw System is a trademark of Kval Incorporated Copyright 2014 Kval Incorporated All rights reserved Beckhoff TIw nCAT 2 and EtherCat are registered trademarks and are licensed by Beckhoff Automation GmbH Windows 7 is a registered trademark of Microsoft Corporation All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated Contacting KVAL Customer Service For further information about this manual or other Kval Incorpo rated products contact the Customer Support Department e Mailing address Customer Support Department Kval Incorporated 825 Pe
5. Variable Frequency Drives interact with hinge and faceplate routers width adjust motors and feed motors If issues occur error codes are displayed on the VFDs To help troubleshoot refer to the VFD manuals located in the High Frequency Panel for lists of the error codes See About the Electrical Panels on page 2 13 for loca tions of VFDs Using the Reset Buttons In some rare occasions an electrical spike may cause a VFD to shut down On some options reset buttons are located on the door of the VFD panels The button contains the VFD function printed on the button If a VFD is tripped to OFF the button will be lit To reset a VFD 1 Push lighted button to reset the indicated motor c If the button light turns off continue with production d If the button stays lit find the source of the down motor printed on the but ton For example if the feed thru motor is not working at operator station turn the motor on and off to reset e If issue continues trace the path of the circuit on the electrical diagram and troubleshoot further or contact our Service Center See Getting Help from KVAL on page 1 13 VED Reset Buttons FIGURE 5 22 VFD Reset Buttons Note The number of reset buttons depends on the machine type and option The fig ure above shows a machine with 11 VFDs KVAL 979 2 Operation Service Manual 5 15 Troubleshooting the Air Cylinders m Troubleshooting the Air Cylinders Mo
6. 2 Miter Trim Saw SyStemM unsunnnnunnnnnnnnnnnn 1 2 ADOULTAUS MANU Alena een AEE EAEAN 1 3 Sale Pie see 1 4 Safety Sheet Sign Off SNEG esii ann a aa 1 4 Safety Terminology of Labels uuuu uuuu000000n000nnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 1 4 SalelyGlldelines n2 seinen 1 4 LOCKOUT Tagout POC COUN 2 PPRERE ER REINER ARAREPEEBERDBEHEMEEEEORERENEEBERTERBEEFARENGE 1 8 Follow the P R O P E R lockout rule Of tnumb uueennaneennnnnnennnnnnnnnnnnen 1 10 Zero Enerav Io State UD een ei 1 11 Zero Energy State to Start Up to Operating State nununnnnnennnnnnnn nenn 1 11 Getting FIED Ir om AVA Lissie 1 13 On Line Help anne 1 13 Product Return Procedure uzu auu000a0000aan00nnnn0nnnnnunnnnunnnnnunnnnnnnnanunnnnnnn 1 13 Salely SIGN Ol Sheet 1 16 ANO O THE OD GIAO i iin seen nebenan anna ensure 1 16 Chapter2 Operation of the 979 2 OPET Or S OU ee 2 2 WIRE CC SEGUON carina 2 3 OO lr edlen 2 3 Operator taiese a een ae 2 4 OUT FCC ne een een 2 4 ADOUT the EICCIICAl Panel S aus a EREA 2 5 About the Salely CUNA rosanero 2 6 Description of the Six Light Panel uzuunnunennnanennanunnnnnnnnnnnunnannnnnnanunnn nenn 2 7 ABOULSENSOFS Eee 2 8 QUICK SlAllasse ss ee nina 2 9 Powering Operations for the 979 2 arennnnnnanunnannnnnnunnnunnnnunnnnnnnnen 2 11 How to Power Up the 979 2 ansunnnaunnannnnnnnnunnunnnnnnnunnnnunnnanunnnnnunnnnnnnnnnnnnn 2 11 HOME ING 979 2 ae 2 12 How to Power Down the 979 2 aeennnnnnanunnnnnnnnununnnununnnnnnnnnnn
7. Help On machines with a Beckhoff PLC and an internet connection our service team are able to con nect run and troubleshoot your machine Ask about this procedure when calling are service team See Chapter 3 System IT Administration on page 3 1 for more information Product Return Procedure If you ve contacted Kval for help and it is determined that a return is necessary use the procedure below to return the machine or part Note Non Warranty returns are subject to a 15 restocking charge 1 Obtain the packing slip and or invoice numbers of the defective unit and secure a purchase order number to cover repair costs in the event the unit is determined to be out of warranty KVAL 979 2 Operation Service Manual 1 13 Getting Help from KVAL 2 Reason for return Before you return the unit have someone from your organization with a technical understanding of the machine and its application include answers to the following questions e What is the extent of the failure reason for return What are the relevant error mes sages or error codes e How long did it operate e Did any other items fail at the same time e What was happening when the unit failed e g installing the unit cycling power starting other equipment etc e How was the product configured in detail e Which if any cables were modified and how e With what equipment is the unit interfaced e What was the application e What was the sy
8. VFD Troubleshooting ccateposnsecesteicabines aneeainaivens acaba wioenseeaaiees 5 15 Error Checking on the Variable Frequency Drives ceeeeeeeeeeeees 5 15 sine the Reset Butions eating 5 15 Troubleshooting the Air Cylinders uessssesesseeeeeeessnnnnnnnnnsssnnennnnnnnnnnnennenennnnnen 5 16 Adjusting Cylinder Extension Speed _ ueeessssssssssssssseeeennnnnnnnnneenneeennnnnn 5 17 Adjusting Cylinder Retraction Speed _ eeeessssssssssssseseeeennnnnnnnneenennennnnen 5 17 Adjusting Limit Switches seien a aan 5 18 Refer to the Air and Electrical drawings provided with delivery of the machine The drawings are normally located in the Electrical Note Panel If copies are unavailable contact the KVAL Service Department Have drawings numbers model number and serial number of machine readily available 9 1 About Motion Control About Motion Control This section describes the positioning systems found in KVAL machinery There are three bas c types of motion control methods used in KVAL Machinery Sequencing Sequencing is a series of events executed in a predetermined order Most KVAL machines use a form of sequential motion control A typical series of events for a KVAL machine are 1 Move the product into position 2 Clamp the product 3 Make the cuts 4 Unclamp the product 5 Move the product out Incremental Incremental motion control is used when the load is required to be moved wit
9. data can be entered to compensate for differences between measured data and expected results For example slight changes in positioning may occur after changing to a new tool Data is entered into the Offset box and combined to achieve the Actual parameter The results are stored in permanent memory Running a Reference Cut If you notice any changes in the cut locations run a reference cut Run a known good profile After the tr m s machined measure the results e The Base is the start up reference e The differences between the template and the measured either positive or negative are entered into the Offset entries e The Actual is the combination of the Base and the Offset entries which is the final result About Motion of Servo Motor The figure below shows the motion of the X axis servo motor Use the figure below as a refer ence when calibrating the machine The reverse direction equates to a negative number and the forward direction equates to a positive number when entering data into the calibration menus Use this information as a guide to help input the directional data in the calibration routines Red Reverse Direction X Axis Servo Motor Green Forward Direction 2 22 KVAL 979 2 Operation Service Manual About the Setup Screens Entering Calibration Data If there s a number in the Base box Click Combine with Offset to combine both num h Base Offset Actual bers 0
10. the cylinder O rings are damaged and air is passing from one side to the other side of the cylinder which means the air is exhaust ing through the solenoid valve It maybe is necessary to purchase a rebuild kit or a new cylinder c If the valve is not receiving an electrical signal for instructions It might be necessary to call in a specialist or check with KVAL customer service at 1 800 553 5825 5 If an Air Leak is coming from an exhaust port on the solenoid air bank a Check the solenoid for the manual override If the solenoid has a manual over ride you can push each of the buttons one at a time When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty Adjusting Cylinder Extension Speed Air Supply Cut Aur Supply In aa Fr Adjusting Cylinder Retraction Speed Air Supply In Air Supply Out De Not adiust Factory Set Clockwise te slow cylinder movement Aur Supply In flow conirol Counterclockwise to speed up cinder movement XQ oF KVAL 979 2 Operation Service Manual 5 17 Adjusting Limit Switches m Adjusting Limit Switches If a machine suddenly stops in mid cycle check the limit switches A worn limit switch arm or a mis adjusted limit switch is more than likely the cause Another potential cause is faulty photo eyes for details Depending on the model of limit switch on your machine the pre travel amount o
11. the end stop for the cut angle The end stop distance is determined by the fixed head cutting angle e For 45 degrees set the end stop for the same distance as the stock width e For O degrees set the end stop distance for O inches Set to Stock 0 Width inches 4 Set the front edge clamp distance on each head to the same as the stock width 5 Set the jamb clamp width air valves For stock less than 3 br inches the valve must be slid toward the input side of the machine For stock greater than 3 inches the valve must be slid toward the out feed side of the machine 6 Load the Hopper 7 On the Touch Screen press and hold the Start Saw button to start the saws 8 Press the feed in foot pedal to start the machining of the product NOTE Wide jamb mode has better clamping ability than narrow jamb mode tighter clamping produces cleaner saw cuts Wide jamb mode can be used on narrow stock The disadvantage is that wide jamb mode is slower by about 3 boards per minute 2 16 KVAL 979 2 Operation Service Manual NL Description of User Interface Screens Description of User Interface Screens This section describes the user interface screens The user interface allows the operator to use a touch screen to control the tr m cutting process auto run manually run the tr m store tr m pro files and use diagnostics to help troubleshoot the 979 2 Screen Selection Menu Map Below are
12. to the lockout center Lockout Tagout Guidelines aa m e e Place atag on all padlocks On a tag each Cam roel ay operator must put their own name and date k These locks are only to be removed by the once Sg person who signs the tag al e If more than one person is working on the 3 machine then each additional person places a em poo lock and tag on each disconnect fe re e Only each operator may remove their own lock and tag KVAL 979 2 Operation Service Manual 1 9 Safety First Important When many people are all working on the same machine you will need a multiple lockout device such as the one shown here Follow the P R O P E R lockout rule of thumb eT Process shutdown Ras Recognize energy type electrical pneumatic mechanical etc Diss OFF Shut off all power sources and isolating devices er Place lock and tag eer ENERGY Release stored energy to a zero energy state R 0o Recheck controls and test to ensure they are in the OFF state 1 10 KVAL 979 2 Operation Service Manual AL Zero Energy to Start Up Zero Energy to Start Up Zero Energy State to Start Up to Operating State Starting the equipment properly is just as important as the lockout tagout guidelines in terms of safety Start up Guidelines The following guidelines below should be followed to start the equipment Inspect The equipment must be inspected for proper adjustment before start
13. 2 Operation Service Manual Ca Powering Operations for the 979 2 Powering Operations for the 979 2 This section describes how to power up and to power down the 979 2 Powering up the system includes e Applying power to the entire system e Starting the Control Circuit Powering down the system includes e Shutting down the control power e Removing power from the entire system How to Power Up the 979 2 1 Ensure factory air is applied to machine and main air supply is turned on 2 Check to make sure all E Stop buttons are out Note A pop up is displayed on the user screen if an E Stop is pressed The pop up will indicate which E Stop has been activated 3 Make sure the electrical disconnect the electrical cabinet is turned to the ON posi tion 4 Switch the green CONTROL TRANS FORMER switch to the ON position It should light up 5 Push the green START MACHINE button to boot up the machine Start 6 All lights on the status light panel on the electrical box should be illuminated See Description of the Six Light Panel on page 2 7 Note If a status light does not turn on during the power up process see Troubleshooting with the Status Light Panel on page 6 7 for assistance in identify ing the issue KVAL 979 2 Operation Service Manual 2 11 Powering Operations for the 979 2 Note EZ Screen Startup When power is applied to the EZ Screen emitter and receive
14. 50000 30 00000880 50000 2 Click the to Offset to display the keypad In combine Ms Clear keypad enter the positive or negative amount with Offset BE Offset Offset to correct the length of the trim Click the green check button to enter the data 13 BONN a If the board is too short add the difference between expected my Pee wv results and the measurement Fi Gamal bas x b If the board is too long subtract the difference between I aaa lene expected results and the measurement ae z 3 If itis correct go back to the calibration screen and click Combine Keypad with Offset to combine offset and base to complete the calibration Click the Clear Offset button to clear any incorrect number in the Offset box 4 5 Run a second cut and recheck the result 6 If the result is off repeat steps through 3 7 If itis correct go back to the calibration screen and click Combine with Offset to combine offset and base to complete the calibration Note Click the Clear Offset button to clear any incorrect number n the Offset box KVAL 979 2 Operation Service Manual 2 23 About the Setup Screens About the Machine Calibration Screen The Setup button leads to the Machine Calibration screen In this screen you can perform machine calibration of the following Individual parameters for each cut mode e System wide or all cut modes as a set Status Walling for START button Servo Head Disabled e
15. Back Up Icon on the Desktop to back up your data The data is stored in a backup folder in your Windows directory It is recommended to set up a back up schedule to save your data on a regular occurrence The KVAL service team would be happy to help If any questions occur contact our service team at 800 553 5825 or at www kvalinc com About Remote Connection to KVAL Service Remote access is a powerful tool to help fix issues that occur with the 979 2 machine With the remote access our KVAL service technician is able to observe your user screen in real time read and adjust programming code For 979 2 access a separate computer must have Beckhoff soft ware installed that is connected to the Intranet connection on the machine controller KVAL 979 2 Operation Service Manual 3 3 System IT Administration 3 4 KVAL 979 2 Operation Service Manual CHAPTER4 Maintenance of the 979 2 This chapter describes preventative maintenance steps for KVAL 979 2 The content s geared to guide technicians to keep a regular maintenance schedule for your KVAL machine Keeping your KVAL machine maintained is an important piece for successful operation of your production pro cess Chapter 4 ata Glance Maintenance schedule aussen 4 2 Daily sense nes en ass has sce ae 4 2 WECKIN oe ee nr Eee ne 4 2 Six Monti Checkups rarene a a 4 3 Eubrcation Requirements Atsanidercahian Nake hes aioe ee ee ae 4 4 Linear Bearings Flange Bear
16. Config Base Offset Actual If all the length f specification th 0 00000890 00000 all the lengths are out of specification the same amount Use this menu to adjust the cutter heads ne KVAL 979 2 Operation Service Manual 2 25 About the Setup Screens About Assigning a Pre set Follow the steps below to assign a pre set length to a button 1 Select the desired Cut Mode 2 Push a preset button until it turns green MB e 3 Push the Modify Pre sets button to go the Pre set menu u Manual Setup Menlity 4 At the Pre set menu enter a title that pis Waiting tor a aan Saree Ts Da will appear on the main screen but ton Decimal Input Fractional Input 5 Enter the length in either decimal or fractional measurements 6 Select the Save button 7 Select the Main button to go back to the main menu The previously selected button will have the title and length 2 26 KVAL 979 2 Operation Service Manual About Manual Operation About Manual Operation From this screen you can control certain functions of the machine in manual mode This screen is mainly used in troubleshooting checking cut specifications and maintenance Enter the speed desired and press and hold the Close or Open Button until the Saw Carriage moves to the desired location Saw Carriage AG UM Press the Exit Application button to close the
17. Hours of Machine Operation or six months AGMA 8 gear lube of operation MOBILUBE HD 80 W 90 or equivalent Daily e Blow off dust from the entire machine Wipe down the outside of the machine with a clean dry cloth e Check tooling for wear e Wipe off the photo eyes with a clean dry cloth and check to ensure that all fastening nuts are snug CAUTION Fastening nuts as well as eyes are plastic and threads can strip easily as Fastening Nuts e Check the air pressure to make sure it is set at 80 psi to100 psi e Check the air filter water trap Empty it if it is full Weekly e Check the machine for smooth motion through a complete cycle e Clean linear bearings and the chrome shaft with a clean dry cloth then lubricate 4 2 KVAL 979 2 Operation Service Manual Maintenance Schedule e Inspect lock flow controls Adjust 1f required ae Adjustment knob wea A Tightening nut so e Check all air lines amp electrical wiring for kinks or rubbing e Refill lubricator with an ISO 32 standard hydraulic oil use KVAL part SYS LUBEG Six Month Checkups e Wash filter and lubricator bowls with soapy water e Grease all bearings and tighten all bolts Access to some grease fittings is difficult and will require a special needle point grease tip supplied with your system e Clean and lubricate all slides and cylinder rods with dry silicone spray e Tighten all bolts e Backup computer software See
18. OFF If the Start light remains unlit push in the Start button and hold it in while a second person checks for volt age between 2 and 75 If there is 110 VAC replace the ACR relay If there is no voltage while the button is held in check the wiring 24VDC Light OFF First solate the power supply Check between DC and DC for 24VDC If no DC voltage disconnect the output V and V wires from the 24VDC power supply and check for DC voltage where those wires were disconnected If no voltage Check the input side for 110 VAC If no 110 VAC check the fuse If there is 110 VAC and no 24VDC replace the 24VDC Power Supply Input 110 VAC Output 24 VDC If there is 24VDC Reconnect the output wires to the 24VDC power supply Trace the output wire to the DC terminal block Disconnect all 24V positive wires from the DC from the DC terminal block except the output wire from the 24VDC power supply Check for 24VDC at between any DC and DC terminal on the DC Terminal block Reinstall the 24V positive wires one by one checking for 24VDC after installing each If at any point no voltage is found trace the last reinstalled wire and check for shorts 5 14 KVAL 979 2 Operation Service Manual AN WAN Troubleshooting Electrical Problems About VFD Troubleshooting This section describes some troubleshooting tools for the VFDs Error Checking on the Variable Frequency Drives VFDs
19. Overview of the 979 2 Miter Trim Saw System Overview of the 979 2 Miter Trim Saw System KVAL model 979 2 Miter Tr m Saw is designed to cut casing for doors and w ndows at rates up to 25 pieces per minute for softwood material Saws pivot between either 0 or 45 degree posi tions The CNC index system will automatically compensate for cut length by adjusting the dis tance between saws The 979 2 saw heads cut down from above the face of the casing to eliminate any tear out on the face There is also a chip out support below the saw to prevent any deflection in thin casing as the saw passes through it This is especially important when cutting MDF casing or pre finished casing This design allows the scraps to drop below the machine into waste bins Not included without assistance from compressed air nozzles The air consumption of the 979 2 operating at maximum capacity is only 8 CFM The 979 2 will miter side casing with a 90 degree trim on the bottom up to 98 long on the short side of the miter Head casing mitered on both ends can be cut as short as 12 3 8 measured on the short side The feed hopper may be easily adjusted to accommodate material up to 4 1 2 wide and up to 1 1 4 thick The pieces of casing are fed from the hopper by a reciprocating dog system The feed dog systems on each carriage are tied together with a timing shaft to insure that each piece of cas ing is precisely positioned under the saws ev
20. Press Home Machine after Reset Machine About the Preset Selection Button Group Pressing a preset button calls a stored length of the casing to be machined There are 56 stored presets for each cut mode The cut modes are e 45 deg 45 deg e 45 deg 00 deg e 00 deg 45 deg e 00 deg 00 deg To choose a preset a B 1 Select the cut mode The cutting heads will move to 45 deg or 0 deg depending on choice 2 Select the desired preset button Em af EZ 3 Select the Load the Cut Parameters Button The parameters will be dis played in the box BDA EN orig 1 2 H mr rim 4 Push and hold the black button to move the Right Head into position The machine is now primed to perform See for full operation steps To assign a preset to the button See for more information 2 20 KVAL 979 2 Operation Service Manual Description of User Interface Screens About the Manual Parameter Menu Cut Length If the preference is not to use the preset buttons manually set 0 0000 the parameters To manually set the length and the quantity of the casings use mntihr this menu The process is Quantity 1 Enter casing length desired 2 Set the desired quantity The machine will stop after the quantity is reached 0 quantity will keep running until operator stops the machine 3 Select the Load the Cut Parameters Button About Choosing Feed Operations
21. Still has power approved lockable disconnect ee Perlen circuit In addition to this equip ment you must install an approved disconnect for the electrical power supplying this machine When opening the cabinet you must first turn off the disconnect switch When the cabinet door is open there is Still power on the top side of the disconnect switch Some machines are powered by more than one supply located at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Before Conducting Maintenance Prior to performing any maintenance repairs cleaning or when clearing jammed debris you p ANG FH must disconnect tag out or lock out the elec trical and air pressure systems This should be Be USE LOCKOUT done in accordance with applicable state and OS BEFORE WORKING or federal code requirements Xes ON EQUIPMENT 1 6 KVAL 979 2 Operation Service Manual Safety First Compliance with Codes and Regulations KVAL advises that you request an on site state safety review of your installation of this machine This is to ensure conformance to any additional specific safety and health regula tions which apply in your geographic area Other Hazard Control Action If you believe any part or operation of this machine is in Ret aldadl
22. URE 4 13 Example of a Typical Ball Screw Important Make sure to clean excess grease to avoid contact with feed belts clamping areas or the product Description of Air Input System The air input system takes in shop air and supplies clean dry air CDA and lubricated air to the machine The clean dry air is diverted to blow off nozzles The lubricator located after the CDA filters delivers the lubricated air to valve banks and air cylinders Shop Air Input Lubricated Air Output Air On Off Knob Lubricator Muffler Filter Ter 3 Pressure Gauge with adjust Clean Dry Air CDA to purge Air Blow Off FIGURE 4 14 Typical Air Line Filter and Lubrication System KVAL 979 2 Operation Service Manual 4 5 Lubrication Requirements Adjusting the Air Line Lubricator Using the knob on the top of the lubricator adjust until one drop per every other cycle is used as observed through sight glass Sight Glass When the oiler has run dry Top of Lubricator open the knob all the way until flow begins Once you have a steady flow tighten knob back down until you have one drop per every other cycle Drop will form at end of cane shaped tube visible inside glass Priming the Air Line Lubricator New and used machinery run out of oil from time to time It is a good practice to check your machine lubricator to insure that it is putting the proper dose of oil in the air lines Usually 1 drop of oil ever
23. Use this menu to set the feed speed adjust for a wider width casing and apply a kerf cut Option A Note KVAL strongly recommends using the Wide Jamb selection on cuts This setting makes good cuts with maximum efficiency About Turning on the Saw After the Parameters are loaded start the Saw H 1 Verify machine area is safe to continue machin amp ing A SAWS OFF 2 Locate the Saws bottom on the lower left had cor 3 ner of the main scree 3 Press and hold the SAWS OFF button for 3 seconds 4 The button will display SAWS STARTING you will hear the machine starting up Warning The Saws are running now DO NOT UTIO put your hands near the saw blade 5 The machine is ready to start working when SAWS SAWS ACTIVE ACTIVE is displayed on the button 6 After machining is completed press the SAWS ACTIVE button to turn OFF the saws During machining it is recommended to use this button to shutdown the saws This will save time of booting up the machine See How to Power Down the 979 2 on page 2 13 f shutting down for the night KVAL 979 2 Operation Service Manual 2 21 About the Setup Screens About the Setup Screens Select the Setup Button on the Main Screen to open access to the Setup Machine Calibration screen Select the Modify Pre sets button to assign values to the preset buttons on the main screen About Calibration Data In the Machine Calibration Screen
24. ab and place a padlock through the hole Place your tag on the padlock as per the tagout guidelines below see illustration below When multiple people are working on the machine each person needs to have a lock on the handle in the extra holes provided EEE b Turn the disconnect switch on the larger high frequency panel to the OFF position Then pull out the red tab and place a padlock through the hole Place your tag on the padlock as per the tagout guidelines below 1 8 KVAL 979 2 Operation Service Manual Safety First 5 Turn the main air valve to the OFF position and place a padlock through the hole see illustration below NOTE Place your tag on the padlock as per the tagout guidelines below 6 Once the locks and tags are in place and all personnel are clear attempt to operate the machine to ensure equipment will not operate 7 Maintenance or repairs may now be completed The person performing the work must ensure all tools spare parts test equipment etc are completely removed and that all guards and safety devices are installed 8 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put n an unsafe condition when re energized 9 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 10 The tags must be destroyed and the locks and keys returned
25. at aa Machine Calibration 45 deg 45 deg Miter Stop Adjustment system Wide Config Annee Offset Actin Base Offset Actual a5 en aF deg SE Offset Actual e 00008 Cita arme Diet ert x 00 dag 45 00 FEST 45 FE Bane ones Actual ori Actua En 45 ze 00 deg cs Actual p o0o00p 00000 Cote ml Ce A ein iias e Cem tee et 00 deg 00 deg Bass ELETE Acal o ooooogo 00000 Ofna Dimmi er Ten f Current Servo Position FIGURE2 8 Setup Menu 2 24 KVAL 979 2 Operation Service Manual About the Setup Screens About Adjusting Each Cut Mode 45 deg 45 deg Ifa discrepancy noticed on one of the cut modes and not all of 0 00000 oocoo Aa them use this menu to fine adjust the cut If the length on the short side is not in specification find the difference between the expected results and enter into the off 00 deg 45 deg set box See on page 2 23 for more detailed instructions ES E i 45 deg 45 deg Check Length 45 deg 00 deg Adl _ KH riui 00 deg 45 deg Check Length a MH 45 deg 00 deg Check Length 00 deg 00 deg Check Length q H About the Miter Stop Option Miter Stop Adjuntment JE Hij Be aba eek Jc teal If a discrepancy is observed on the miter stops use this menu to adjust stop positions About Adjusting System Cut Modes System Wide
26. automation the station interface replaces manual setup thereby saving time Cutting parameters can be stored and retrieved by one touch The Touch Screen logic also includes management functions such as Daily and Lifetime Totals See Description of User Interface Screens on page 2 17 and Quick Start on page 2 9 for more information Touch Screen Interface Controls e Emergency Stop e Move Head e Start boot up Stop Turn ON or OFF Control Transformer FIGURE2 3 Operators Station with touch Screen Interface Out Feed The figure below shows the key parts of the out feed of the machine Ta Out Feed Area Fin l ished Product is fed Safety Curtain Electrical Safety Curtain out of the machine Panel 2 4 KVAL 979 2 Operation Service Manual Ca Operator s Tour FIGURE2 4 Out Feed Key Parts About the Electrical Panels The 979 2 has a Main Electrical Panel Figure 2 5 below is an overview of the location of assem blies in the panel The Main Electrical Panel e VFDs Variable Frequency Drives to interact with hinge and faceplate rout ers width adjust motors and feed e Contains the PLC Programmable motors Logic Controller e Supplies voltages to the machine e Contains servo drives to interact with the servo motors Axis and Lock Loca tion in the front and back sections Warning High Voltage is present in this panel at the top of the Three Phase Input eve
27. aw Extend E plih MOL yiii baiiia EIN ep Ba Motos KMotort ontact Intilired AT JOIE i Diit ei Serer Manages Lew Manager initiired PSOLIDAE Saw Location Asin HAc laiih CFOS OF Wet Serve Haad Manager Haadklanaget Inkliend AOE liner Codie kenn 5 Kae beine SOO 04 ner Catenion 100 Ken Beine rt lie Cade tions Di KC er baii pei AA HS Calibration KCalMumber balled AS SO Calibration AE ainar aiti gi RO Calibration KCaiMumber lett ped EA 00_ 09 Calibration KC aifiembar bnitil ped 0 08 et Kekse Cameration WLalHumten Initticed GPO ONE tii Taskila Tash Manier heeded Current Servo Posion FIGURE2 10 Diagnostic Screen 2 28 KVAL 979 2 Operation Service Manual CHAPTER 3 System IT Administration This chapter describes the KVAL 979 2 controller The controller s an on board computer that supplies the user interface and controls the operation of the machine With the controller KVAL can remotely help troubleshoot your machine Chapter 3 at a Glance System IT Administration 3 2 About the 979 2 Computer 3 2 Connections on the PLC 3 2 Backing up the Computer 3 3 About Remote Connection to KVAL Service 3 3 3 1 System IT Administration m System IT Administration For optimum support the 979 2 requires internet access With internet access KVAL Service Support will be able to access your machine through your company s Intranet and help solve any issues that m
28. aw assembly springs Removal of the belt guard requires the operator to first remove the saw assembly guard Feed Assembly Guard Located on the inboard sides of both saw carriage feed dog assemblies The feed assem bly guard protects the operator from getting hands caught inside the moving parts of the feed assembly The guard provides protection against possible amputation cuts bruises broken bones NEVER ACCESS THE FEED ASSEMBLY GUARD WHILE POWER IS ON KVAL 979 2 Operation Service Manual 4 9 Mechanical Adjustments Removal and Replacement There are eight socket heads securing bolts on each of the two feed assembly guards The fastening bolts are located in two rows of four bolts on the ends of the guard s toward the front and back of the feed dog assembly Kerf Blade Guard for optional Kerf Saw Mounted directly over the kerf blade s on both kerf routers located on either end of the 979 2 The kerf blade guard is designed to protect the operator from the kerf blade whether or not the machine s operating The kerf blade guard protects the operator from possible amputation eye injury from air borne dust and wood particles and cuts NEVER ACCESS THE KERF BLADE GUARD WHILE POWER IS ON Removal and Replacement The Kerf Blade Guard s is secured by two bolts on either side of the kerf blade guard NOTE These guards are present only when the kerf saw option has been installed 4 10 KVAL 979 2 Operation S
29. ay occur Connection to the Intranet is achieved by interfacing with the 979 2 con troller The location of the Intranet connection is identified in the figure below RJ45 to Intranet About the 979 2 Computer The 979 2 uses a Beckhoff CPU module as a PLC Programmable Logic Controller In addition to the CPU and the chipset the module also contains internal main memory The computer has a removable Compact Flash card from which it boots The controller uses a Windows ri operating system w th TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include e A smart power supply to connect to EtherCat terminals This supply contains a LCD to display system and user messages e A DVI USB module to connect to the user interface e An Ethernet module to connect to the servo amplifiers Connections on the PLC The CPU module is located in the upper left corner of the Electrical Panel See About the Electri cal Panels on page 2 5 The figure blow shows a common PLC setup For detailed information on the PLC see the machines electrical print Interfaceto Servos RJ45 to Intranet DVI USB Module Compact Interface to to User Interface Flash Card Frame FIGURE3 11 Connections on the Controller 3 2 KVAL 979 2 Operation Service Manual AL System IT Administration Backing up the Computer Backups keep your data archived in case of a rare system crash Click the
30. chanical motion Caution control system If servicing the 979 2 follow the safety guidelines described in Failure to do so can result in damage to equipment and or serious injury to personnel 979 2 Guard Placements and Purpose The following information gives a description of the mechanism being guarded and the hazard being guarded against Saw Assembly Guard Located on both saw carriages covering the entire saw assembly The saw assembly guard provides protection from possible amputation broken bones eye injury from dust and wood particles cuts and bruises There are saw blade access doors on the back side of both guards NEVER ACCESS SAW BLADES WHILE POWER IS ON Removal and Replacement There are four bolts securing each saw assembly guard There are two bolts on the top of the guard s and two bolts at the base of the guard s toward the end s of the machine Removal of the saw assembly guard is a two person job Never attempt to remove the guard by yourself Belt Guard Located on both saw carriages INSIDE the saw assembly guard toward the outboard front of the saw assembly The belt guard protects the operator from getting hands caught between the belt and the belt pulleys The guard provides protection from ampu tation cuts bruises broken bones NEVER ACCESS THE BELT GUARD WHILE POWER IS ON Removal and Replacement There are two bolts securing each belt guard located on the flange of the guard near the s
31. e shooting starts with looking at the whole machine where every part is suspect Then narrowing down the view to the bad part Ask Ask basic questions For example e What was the Machine Trying to Do e What Was the Machine Trying to Do Next e Was the machine working before e Did it happen on first power up or during process Narrow Narrow or determine the sequence and subsystem where the issue occurs For example e Did the issue happen when door was being fed in e Is the router not cutting e Is the cut out of specification Verify Verify or analyze the subsystem assembly that is responsible for the issue For example e How is the subsystem supposed to work e What is keeping the subsystem from working e Check the Positioning System Follow the circuit from the Controller output to the Load and check for component failures Using Sensors to Trouble Shoot e Photo Sensors often get dirty Make sure they are clean If they are not clean debris blocks the signal e Check output voltages of the sensors in the active mode The voltage should effec tively equal 0 VDC e Check the output voltages of the sensors in inactive mode The voltage should effec tively equal 24 VDC KVAL 979 2 Operation Service Manual 5 7 Location of Sensors on 979 2 WAL Location of Sensors on 979 2 Figure 5 21 below shows the sensor and switch locations on the 979 2 The T designation rep resents an input to the PLC and the
32. equency drive VFD s used n KVAL machinery The figure below shows a block diagram of a typ cal motor drive circuit with typical voltages Line Voltage Power Should measure Should measure Control Voltage Line Voltage here 24 VDC here Fuse s Should measure PLC Line Voltage here Output ON STF Forward Power Run OFF STR Revers 2 Input 300 EN l Motor Run Light OFF i hould be ON Drive shou OFF RL Power SD COMMON Output Should display the Motor Frequency Control Circuit x7 Motor Common ON FIGURE5 19 Common Motor Drive Control KVAL 979 2 Operation Service Manual 5 5 About Motion Control Typical Positioning System Pneumatic Circuit A control valve solenoid is used to drive cylinders to move different loads in the machine For Example extending and retracting router drill clamping a door Should measure Control Voltage PLC Output nf Control Circuit Common 24 VDC here Coil Input Control High Pressure Air Air Input Control Valve Air Output FIGURE5 20 Common Pneumatic Block Diagram Cylinder Extended Should have High Pressure air here Should have High Pressure air here 5 6 KVAL 979 2 Operation Service Manual AL Troubleshooting Basics Troubleshooting Basics Good troubl
33. eration Service Manual 4 15 Mechanical Adjustments 4 16 KVAL 979 2 Operation Service Manual CHAPTER5 Troubleshooting the 979 2 This chapter describes troubleshooting steps to help technicians solve issues that may occur with your KVAL machine If help 1s needed call or contact our KVAL Service team at 800 553 5825 or http www kvalinc com Chapter 5 at a Glance About Motion Control ae a 5 2 Basic ContmowCmeuit lt aeacct aise acetic enasesecaieadsc at ehswaneensa meee a ataacnaeaeie 5 2 Typ cal Positionne Systems geeks iesesae ces a E here alcatel 5 4 Common ContactOr Control rien 5 4 Common Motor Drive Control oe eeccccccccccececeessseeeececceeceanesseeeeeees 5 5 Typical Positioning System Pneumatic Circuit oo eeseeeeeeeeeees 5 6 Troubleshe tinge Bas cs san 5 7 Usine Sensors to TTOuUDIE SNOOL essen 5 7 Location of Sensors on 979 2 ee eier 5 8 Troubleshooting Electrical Problems _ ussssssssssesssseeeeennnnnnnnnneeneeennnnnennnn 5 9 If the Power Stops During Normal Operation esssssesesesssssssseressssssssseerees 5 9 Troubleshooting with the Status Light Panel _ unenseeeeeeeeeeen 5 10 Control Power LICHL OFF isses 5 12 Overload Rely Cent OFE sesesiicarensoutaiiadecnsehuist A 5 13 Stop erent OP iga a ta eta ree aenthencs eta eae enna 5 13 SUC STOMP OIE rare een enter tceacedmenet oie 5 13 ST rt EIEHt OFF arrean a 5 14 ZANDGCTASNC ORE arten 5 14 About
34. eration Service Manual description2 7 EtherCat smart power supply3 2 terminals location3 2 ethernet module connection to servo amplifiers3 2 F flange block bearing maintenance schedule4 2 front section status feedback2 18 G gear box maintenance schedule4 2 H hinge spec group description2 21 home button description user interface2 20 using2 12 I inductive proximity sensor2 8 in feed section key assemblies2 2 internet access location of connection3 2 remote connection3 2 RJ45 to intranet3 2 intranet RJ45 connection3 2 L LCD display smart power supply3 2 linear bearing maintenance schedule4 2 lockout and tagout Guidelines1 9 lockout procedure1 8 M machine feed back user output2 18 machine feedback front section status2 18 general2 18 servo positons2 18 machine status general feedback2 18 main cal screen group locations2 24 main electrical panel description2 5 main screen interface2 19 maintenance daily4 2 six month4 2 weekly4 2 manual operation interface2 27 menu map2 17 O operator s tour top view2 2 overload relay light description2 7 P pillow block bearing maintenance schedule4 2 PLC battery location3 2 connections3 2 location3 2 location in main electrical panel2 5 power disconnect switches1 8 lock out procedurel 8 power up troubleshooting5 9 powering up and down machine2 11 preset selection description2 20 product return procedure1 13 programmable logic con
35. ervice Manual Ca Mechanical Adjustments Feed Dog Adjustment Procedure Note Normally this adjustment would not be necessary It is provided here for the rare occasion when adjustment is necessary 8 Lockout and Tagout the equipment as per instructions in Chapter 1 9 Holding the right angle of a T Square against the Fixed Head Dog plate adjust the for ward feed stops so both the fixed head middle feed dog and movable head feed dog and the alignment mark all line up Fixed Head Movable Forward Feed Head For Stop ward Feed Stop hen Movable Head g Dog Plate eee L Feed Fixed Head Alignment Movable Head Mark Feed Middle Dog Fixed Head Mid F H dle Feed Dog on ean T Square Plate Movable Head Plate KVAL 979 2 Operation Service Manual 4 11 Mechanical Adjustments m 10 Manually Pull both movable and fixed head dog plates agents the Feed Reverse stops 11 Adjustthe Feed Reverse stop for a gap of 8 15 16 between the forward edge of both Feed Dog Plates and the Feed Forward Stop 8 15 16 Feed Forward Feed Dog Plate Feed Reverse Stop Stop 12 Reinstall the inside covers 13 Remove Lockout Tagout 14 Continue production 4 12 KVAL 979 2 Operation Service Manual Mechanical Adjustments KVAL 979 2 Operation Service Manual 4 13 Mechanical Adjustments 4 14 KVAL 979 2 Operation Service Manual Mechanical Adjustments KVAL 979 2 Op
36. ery time Each cutting head is equipped with a 3 HP 3450 RPM TEFC three phase motor The saw motors have 1 diameter arbors Types of options available Are Option A Spline Saw System Cuts slots for kerf nail in head and leg casing miter Option B Mitered ends on Door stop Is capable of cutting mitered ends on door stop The Option G Auto Calibrated Stops Is an air operated system with calibrated stops that automatically adjust the movable carriage when the saw heads are rotated Option Z Computer Controlled Positioning The 979 2 will be equipped with a computer driven servo motor to position the movable head The system will automatically compensate for the offsets when the cutting heads are switched from 90 degrees to 45 degrees The system will be controlled by a touch screen that will allow the operator to simply enter the short side length of casing to cut The finished length of the casing will be correct for all saw head configurations 1 2 KVAL 979 2 Operation Service Manual AL Overview of the 979 2 Miter Trim Saw System About this Manual This manual contains operation information and service and maintenance information It includes identification of machine assemblies power up and power down steps and informa tion about using the user interface The Troubleshooting and Maintenance sections are directed toward qualified service technicians TABLE 1 1 126_OPSRVDOO 70 KVAL 979 2 Opera
37. f movement from the limit switch arm s resting position to the position at which the switch actuates with a click is either 5 or 20 degrees If the arm is moved to the full extent of its travel and you do not hear the limit switch click the switch needs to be adjusted Use the set screw on the limit switch arm and adjust the arm to acti vate at the desired degree of rotation see illustrations below pa Limit Switch Arm Sat Gowa The ever is adjusted by loosening 3 Limit Switch Arm fe a the set screw A 5 32 hexagon rdan 3 _ key wrench is required Limit Swich Body FIGURE5 23 How to Adjust a Switch 5 18 KVAL 979 2 Operation Service Manual Index Numerics 979 2 description of machine2 2 A air input system description4 5 lubricator4 5 air line lubricator adjusting4 6 priming4 6 air line lubricator maintenance schedule4 2 air valve lockout tagout1 9 B back section group description2 21 back section status feedback2 18 ball screw maintenance schedule4 2 Beckhoff CPU module3 2 computer as a PLC3 2 backing up3 2 3 3 control panel light not on troubleshoot5 12 control power indicator light description2 7 control transformer switch power up2 11 2 13 D diagnostic screen description2 28 dura lith grease bearing lube4 2 DVI USB module location3 2 E electrical panels description2 5 emergency shutdown description2 13 e stop light KVAL 979 2 Op
38. h high accuracy to multiple locations sometimes in multiple directions axes A typical KVAL usage for this system is a computer controlled router in a door light machine where there is great variety in the cut size shape and location Basic Control Circuit This section describes a basic control circuit The Figure below shows a block diagram of a com mon control circuit There are four parts to a motion control system Position Feedback on Optional Positioning Instructions y Optional User Interface Controller Positioning Load Translated System A Positioning Instructions Process Complete OK to move Machine s Other Subsystems FIGURES 17 5 2 KVAL 979 2 Operation Service Manual About Motion Control The User Interface A e Allows communication between the humans and the machine Examples A touch screen a PC or a button panel The Controller e Translates entered information into a form the positioning system can understand e Listens to the machine s other subsystems waiting for the OK to move command e Sends the positioning instructions to the positioning system e Listens to the positioning system for position status if there is a feedback loop e Tells the machine s other subsystems when the move process is completed Examples A PLC or a dedicated motion control board Positioning S
39. ia a A a 4 2 SX MOM GMECKUDS APRFERERRRSRRRPABEFERRAFPEDEDFERESERRFEERAREEELFBEFTEEFEGEESHNBERLTERFEOBERR 4 3 Lubrication Requirements sssrinin aa 4 4 Linear Bearings Flange Bearing and Pillow Blocks ssssssnnnsnnnnnnnnnnnnnnnnn 4 4 Gear Motor Lubrication Requirements uennnanennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnn 4 5 Ba OOW S ioina AAT 4 5 Description of Air Input System sasia a 4 5 Adjusting the Air Line Lubricator u uu2u000000000000nnan0nnnnnunnnnnnnnnnnnnnnnnnnnnnnn 4 6 Priming the Air LING KuUBNGAtor Eee ee 4 6 Lubrication Points on the 979 2 risoun 4 7 Lubrication Points Bottom of Machine uu uauuunuuu0000an0nnnnnnnnnnnnnnnnunnnnnunnnn 4 7 979 2 Miter Trim Saw System MDPC ATION Points Heads misrin ee 4 8 Mechanical Adjustmenis u2 2u000000 000nan0nnnnnnnnnunnnnnnnnunnnnnnnnnn 4 9 979 2 Guard Placements and Purpose uausennnnanennnnnnnonnnnnennnnnnnnnnnnnnnnnnn 4 9 Feed Dog Adjustment Procedure 2z2 22000a200 an0nanu0nnnnnnnnunnnnunn nun nnnenn 4 11 Chapter 5 Troubleshooting the 979 2 ADOULIVIOUOM SONO ee 5 2 Basic GoNnIol Girellsessstnakre a 5 2 IyDleal Pos lioning Sysiemsa ana 5 4 Troubleshooting BASICS u uuu00 n0 Hann annnanunnnunnnnnnnnnnnnnnnnnnnnnnnnnnn 5 7 Using Sensors to Troubl amp Shodt n nn 5 7 L OCAUON Ol Sensors ON 979 2 anna 5 8 Troubleshooting Electrical Problems u0u2u022002000a000n0nannnnnn 5 9 If the Power Stops During Normal Operation zuunnnanennnnanennnnn
40. ing and Pillow Blocks _ nnnneen 4 4 Gear Motor Lubrication Requirements oo ceseesseceeceeeeeeeeeeeseeeeeeeeeeeaas 4 5 BAIESCH WE ee ee T Nee 4 5 Description Ol Alr Input system nee ooh AER 4 5 Adjusting the Air Line Lubricator oo eaa E 4 6 Priming the Air Line Lubricator eseeessesssssoeeesssssssssseccresssssssecceeesssssssecereos 4 6 Lubrication Points onthe 9792 unten 4 7 Lubrication Points Bottom of Machine _ uueessssssssssseseeeeennennnnnnnenneneneennnn 4 7 Iubrication Points Heads sinne ne 4 8 Mechanical Adjustments uses u de 4 9 979 2 Guard Placementsand Purp se erriyan ienn E RR 4 9 Feed Dog Adjustment Procedure _ esssssssessseseeeesennnnnnnnnnsnnenennnnnnnnnnnennnnn 4 11 4 1 Maintenance Schedule m Maintenance Schedule KVAL recommends the following maintenance schedule to ensure that the machine operates properly Refer to this section for steps to perform maintenance TABLE 4 1 Recommended Lubrication Schedule Type of Assembly Recommended Schedule Recommended Lubrication Type Pillow Block Bearing Every 250 Hours of Machine Operation Dura Lith Grease KVAL P N Lube EP 2 Flange Block Bearing Air Line Lubricator One drop of oil every 2 or 3 cycles Either lubricant listed below is approved to Check the lines every week to two weeks KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R amp O Mobile DTE 24 Shell Tellus32 Gulf Harmony 32 Gear Box 2000
41. ing equipment Clean Up All materials and debris must be cleaned up Any combustible materials or old parts used during repairs must be cleaned up and or properly disposed of Replace Guards Replace all equipment guards If part of equipment cannot be properly adjusted after start up with guard on contact the KVAL Service team See Contacting KVAL on page 1 2 Check Controls Confirm that all switches are in the OFF position Please be advised that some com ponents of the machine may start automatically when energy is restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is started Perform Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the personnel alarm before starting the equipment If your operation is more complex your company s comprehensive safety procedure may involve additional steps You will need to ask your supervisor about these procedures The company s lockout procedure should be posted at each machine On larger or long term mainte nance or installation projects the company s procedures must be explained to all new operators and a copy of the company s procedures should be posted on site for the duration of the work The Company s procedures should also include provisions for safely handling shift changes and changes in operato
42. located at key points around the machine The E Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment When an E Stop switch is activated power to the machine 1s killed The machine responds in the same way if you press the STOP button on the operator s station KVAL 979 2 Operation Service Manual 2 13 Powering Operations for the 979 2 m About Modes The four different cut modes are illustrated below See About Adjusting Each Cut Mode on page 2 25 for information about selecting the dimensions for the cut Left Head SS Right Head 45 deg 45 deg Right Head Left Head i Into machine A z 45 deg 00 deg Right Head Left Head i Into machine i j 00 deg 45 deg Right Head Left Head i Into machine i j 00 deg 00 deg E N Right Head Left Head Into machine 2 14 KVAL 979 2 Operation Service Manual Ca Mechanical Set Up Mechanical Set Up After the parameters are loaded form the operator station prepare the machine to process the stack O 1 Adjust both back hopper stops for a hopper width of roughly 1 8 inch larger than the stock 2 Adjust both front hopper stop s height to clear the stock by roughly 1 8 inch Front Hopper Stop Rear Hopper Stop Note Use a 1 2 wrench to Adjust the Bolts Adjustment Bolts for Height KVAL 979 2 Operation Service Manual 2 15 Mechanical Set Up 3 Adjust
43. m components are labeled with numbers that correspond with the electri cal prints included in the electrical box door Computer controlled machines have signals on the computer that light up when the input or out put functions are energized respectively Computer controlled as well as non computer controlled machines have white 120V control power terminal strips This will indicate power supply from the respective circuits PLC controllers also have lights on them for the input and output functions You can easily find out which circuits are failing by watching the lights turn on or off Compare the lights on the IDEC or Beckhoff controllers to the electrical print to determine what systems are being affected If the Power Stops During Normal Operation 1 Check that the input power disconnect switch is not turned off 2 Check that all of the emergency stop buttons are in the normal position 3 Check the Six Lights on the Electrical Panel See Troubleshooting with the Status Light Panel on page 5 10 Lockout and Tagout the main power source 1 Turn the panel disconnect switch in the off position open the electrical panel door 2 Observe the disconnect switches Look for loose or broken wires at the disconnect then at all of the components 3 Check for continuity of all fuses with an OHM meter Fuses need to be removed from the bottom side of the fuse holder before measuring the fuses KVAL 979 2 Operation Service Man
44. me steps in the Quick Start below See Running a Reference Cut on page 2 22 1 Ensure factory air is present at the machine an d the 979 2 main air Power Up supply valve s turned on 4 amp 2 Power up the 979 2 See How to Power Up the 979 2 on page 2 nome 11 3 Home the 979 2 See Home the 979 2 on page 2 12 4 Select the cut mode 5 Select the desired preset button Use Main Screen Cut Length Quantity 6 Select quantity of boards to cut Enter the cut length if different than the pre set 7 Select type of cut 8 Select the Load the Cut Parameters Button The parameters will be displayed in the box Note KVAL strongly recommends usin the Wide Jamb selection on cuts This setting makes good cuts with maximum efficiency KVAL 979 2 Operation Service Manual Quick Start 9 Ensure area is safe On the Operators station push and hold the black button to move the Heads into position 10 Set the machine up for the chosen parame ters See Mechanical Set Up on page 2 15 11 Load the hopper otart 12 Press and hold the Saws Off button until the sequence saws Start Button displays Saws Active 13 Start production by pressing the right the foot pedal SAWS OFF CAUTION SAWS ACTIVE If finished with production and shutting the machine down see How to Power Down the 979 2 on page 2 13 2 10 KVAL 979
45. n of the 979 2 This chapter describes components assemblies and the user interface of the KVAL 979 2 Miter Trim Saw System The content is geared to help operators understand the basic operation of the 979 2 Chapter 2 at a Glance Operators Tour sans ein 2 2 In Ferd Ssection aueserae alle 2 3 POOCPOdIE esse ee ecm tee eee en 2 3 OpPe1alors Slauon pian ae ee ee 2 4 UE BCC eures 2 4 Abo tihe BleetricakPanels cmentarna a a a lls 2 5 Aboutihe Sa y CUNA Seer a a 2 6 Descrip omof the Sx Licht Panel ass au 2 7 ADOUFSENSOTS unseren 2 8 OTCE Dit essen eier 2 9 Powering Operations for the 9792 ana 2 11 Howto Power Uptie9 92 arip a 2 11 Klon iu 2797 euere Reese 2 12 Howto Power Downthe 9792 sure 2 13 Emergency Shutdown and Recovery esssseesssssssssscererssssssssseeeressssssseeeeeeo 2 13 ADoUL Mode unseren 2 14 Mechanical Seyi zen rer 2 15 Description of User Interface Screens eeeeeeeeseeeeeeesssnnnnnnnnnennnnnnnnnnnnnnnnennnnennnnnnn 2 17 Screen Sclection Meni Map eisen 2 17 Machine Feed B ck aeon a a a N 2 18 About COCK OMS Option ass 2 18 Main Screen sedare a time tevaiets 2 19 About the SCEUP Screens eine ee 222 About Gaubrauon Data ea 2 22 R nnins a Reference CH essen 2 22 About Motion of Servo Motor _ eeessssssssssssseeesennnnnnnnnnennnnennnnnnnnnneennennnnnnnn 2 22 Entering Calibration Data aussah a de u 2 23 About the Machine Calibration Screen _ ueesssssssssssseeseeennnnnnnnnneeneeneennnnn 2 25 Abo
46. n with the disconnect off If working on the panel follow the safety protocol as described in Chapter 1 Main Electrical Panel i Input Output Terminals PLC I 7 ne L EI it HT A 110 V 24 V Terminals Control Trans ny ifi ny former HAHN Contactor and Over VFD Section load Circuit Servo Drive FIGURE2 5 Overview of Main Electrical Panel and High Frequency Panel KVAL 979 2 Operation Service Manual 2 5 Operator s Tour m About the Safety Curtain The Safety Curtain provides safety for personnel who enter the defined area when the machine is active If any part of an operator s body is detected in the defined area the machine stops the operation The machine must be reset from the operators station to continue machining The Safety Curtain is composed of an EZ Screen emitter and receiver The emitter has a row of synchronized light emitting diodes LEDs that send signals to the receiver The receivers have a a matching row of synchronized photo detectors that read the signal from the emitter When the signal is blocked of any beam the machine stops To continue machining push the Start button Important The EZ Screen system is aligned at the factory Do not move the emitter or receiver modules This may cause misalignment if the system is mis aligned the machine will not start Product Output Machine will stop if barrier is broken Restart the machine to continue mit
47. nel Training Ensure that all employees who operate this machine are aware of and adhere to all safety precautions posted on the machine and are trained to operate this machine in a safe manner 1 4 KVAL 979 2 Operation Service Manual Safety First car When the Machine is O Compressed Air Never operate the machine without proper eye and protection N e Never reach hands beyond safety cage Servo motors can unexpectedly move quickly e Never clear screws or hinges out of the machine while it is running e Never reach into the router area to retrieve a hinge The router may still be running down after shut down e Never perform any maintenance unless machine is at zero state e Never clean the machine while it is running e Never walk away from the machine while it is running The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief To avoid possible injury lockout pneumalic power before servicing All cylinders on machine are under high pressure and can be very dangerous when ma activated Before performing any mainte nance or repairs on this machine turn off the main air disconnect Lockout and tagout this connection See Lockout Tagout Procedure on page 1 8 KVAL 979 2 Operation Service Manual 1 5 Safety First Electrical Electrical circuitry on this machine is protected by an
48. nennnnnnnnnnnnnen 5 9 Troubleshooting with the Status Light Panel uuennnnnunnnnannnnnnnnnnnnnnnnnnnnnn 5 10 About VFD Troubleshooting san 5 15 Troubleshooting the Air CylinderS sssssssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 5 16 Adjusting Cylinder Extension Sp e ssscssssseccsssseecssseesessseseesseesenees 5 17 Adjusting Cylinder Retraction Speed nuuuuennnnnnnnnnnnnnnnnnnnnnnnnnnnnn nun 5 17 Adjusting Limit SWilches ns 5 18 KVAL 979 2 Operation Service Manual 979 2 Miter Trim Saw System CHAPTER 1 Introduction to the 979 2 Miter Trim Saw System This chapter provides an overview of the KVAL 979 2 Miter Trim Saw System and important safety information to follow when operating the machine Chapter 1 at a Glance Chapter Lara Glance aussen 1 1 Overview of the 979 2 Miter Trim Saw System eeeseeesssseeeennnnnnnsssenneennnnnnennnn 1 2 ADOC Manual rear 1 3 Sale First essen een 1 4 Salety Sheel SENON She sirarne a 1 4 Salety Terminolosy or Labels ana Serien Beau 1 4 Salely Guldelines rinnen 1 4 Lockout Tascut Procedure sense 1 8 Follow the P R O P E R lockout rule of thumb _ usseseeeeennnene 1 10 Zero ENe1sy IO Slate UP arena ine 1 11 Zero Energy State to Start Up to Operating State oe ececceeeeneeeeeees 1 11 Getting Help from KVAD ae 1 13 On EincHeld saisie a a Mu stetaxshor eke 1 13 Product Reuni Proceduie dernei SS 1 13 Salely SIOM OM SHEED unten 1 16 A Notetortne Oper lgt nina 1 16 1 1
49. nunnnnnnunnnnnnnnnnnn 2 13 Emergency Shutdown and Recovery zuanannunnnnnunnnnnnnnnnnnnennnnnnennnnnnnn nn 2 13 POO UL IWIO CES Ananas nase ea 2 14 KVAL 979 2 Operation Service Manual Mechanical SEL UD irssi annia aS 2 15 Description of User Interface Screens ssssssnnnnnnnnnnnnnnnnnnnnnnnnnnn 2 17 Screen Selection Menu MaP u ssscccsssecccceseeecesseeseenseeseesseesenseessonseesees 2 17 Machine Feed Back ee een 2 18 About Lock Outs Option nn nen 2 18 Manh ChE CN eae a 2 19 ADOUL INE Selu Screens ernst 2 22 About Calibration ID Al aiceccusst oececareteueucusess decetunpncesacuyeoevoreccssseutesssesetcans 2 22 RUNNING a Reference Cut u 22200000an00nnnnnnnnnnnnunnnnnnnnnnnnnunnnnnnnnnnnnnnnnn nen 2 22 About MOTION Of Servo Motor anna 2 22 Entering Calibration Dita een 2 23 a ee ern ee users 2 23 About the Machine Calibration Screen uuuennnnannnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnn 2 24 ADOUF ASSIENING a Pre Setasiun ninaona aaa aaa aaaea iisas 2 26 ADOUL Manual Operations 2 27 PIAGNOSUC Screen een 2 28 Chapter3 System IT Administration System I Administralonsss essen 3 2 About Ihe 9792 COMPUTE anna 3 2 Gonneclions ON te PIE ee es 3 2 Backing up the Computer uu2u000200000nnnnu0nnnnnnnnnnnnunnnnnnunnnnnnnnnnnnnunnnnnnnnn 3 3 About Remote Connection to KVAL ServiCe csscsscsecsecesceecuseueeeseeeeneees 3 3 Chapter 4 Maintenance of the 979 2 Maintenance Schedule zn 2 einen 4 2 Dilemma 4 2 WEGRY as e
50. ows 1 Control Power Amber 2 Overload Relay Amber 3 E Stop Amber 4 Stop Amber 5 Start Amber 6 24VDC Green If one or more lights are OFF follow the process below to isolate the cause NOTE Be sure to proceed down the table starting with the CONTROL POWER light STEP 1 Control Power Amber If light is OFF go to item A on page 5 12 STEP 2 Overload Relay Amber If light is OFF go to item B on page 5 13 STEP 3 E Stop Amber If light is OFF go to item C on page 5 13 STEP 4 Stop Amber If light is OFF go to item D on page 5 13 STEP 5 Start Amber If light is OFF go to item E on page 5 14 STEP 6 24VDC Green light is OFF go to item F on page 5 14 KVAL 979 2 Operation Service Manual 5 11 Troubleshooting Electrical Problems A Control Power Light OFF 1 Check if the Control Transformer button is pulled out 2 Is the Disconnect Switch on the main electrical cabinet set to ON Switch 3 Is there 208 220 440 or 575 VAC to the top side input of the Control Trans former If not check the fuses at the Fuse Block and the contacts on the Control Transformer button on the switch panel Typical Control Transformer Input Output High Vac 110 Vac _ 4 Is there 110 VAC between 1 amp 2 on the 110 VAC Terminal Strip If not check the fuse on the output side of the Control Transformer If fuse 1s good check power coming out of Control Transformer
51. perating this machine e I will watch out for other people Make sure everyone is clear of this machine before operation e will always follow my company s safety procedures I have read and understand these guidelines Machine Safety Concerns e I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency e will make sure all guards are in place before operation will turn off the compressed air before loading hardware staples screws etc I will turn off the electrical power for setup e If the machine should operate in an unexpected manner stop production I will immediately and notify a manager a supervisor or a qualified service technician I have read and understand this document and agree to operate this machine in a safe man ner as described above Employee Name print Signature Date Supervisor Safety Officer Trainer Name print Signature Date Note It is recommended you make a copy of this sheet for new operators If a copy is needed you may download a PDF at the KVAL website http www kvalinc com You may also contact our Service Department at 800 553 5825 or email at service kvalinc com 1 16 KVAL 979 2 Operation Service Manual Safety Sign Off Sheet KVAL 979 2 Operation Service Manual Safety Sign Off Sheet 1 18 KVAL 979 2 Operation Service Manual CHAPTER 2 Operatio
52. r each sensor will conduct self tests to detect critical internal faults and prepare for operation If no faults are detected The LED s will be lit as follows Power Fault LED Green Alignment LEDs Yellow OFF Status Clear LED Green Home the 979 2 The 979 2 must go through a homing routine before any operations are performed The homing routine sets a zero reference from which the 979 2 measures its movement and cutting process If power is lost or the 979 2 is re set the homing routine must be performed again to reset the zero reference Press the Home button on the Main Screen touch screen 1 The machine will move to the home position 2 The machine will then move to about the middle of its travel The 979 2 is now ready for work Machine Reset Machine 2 12 KVAL 979 2 Operation Service Manual Ca Powering Operations for the 979 2 How to Power Down the 979 2 1 Push the Stop Button on the operator station Note Make sure Windows is shutdown completely before turning off the machine Hard drive or data may be dam aged if not turned off in this order 2 Switch the green CONTROL TRANSFORMER switch to the OFF position 3 KVAL also recommends that you turn the disconnect 1 switch on the electrical cabinet to OFF this helps reduce possible damage resulting from power surges from electri cal storms Emergency Shutdown and Recovery There are emergency shutdown E Stop switch
53. rigger Photo Eye Detectors contain both emitter and receiver If an object is within the Photo Eye s sensing field light from the emitter is reflected from the object back to the receiver With no object is in front of the Photo Eye a constant 24VDC is sent to the PLC If an object is sensed by the Photo Eye OVDC is sent to the PLC e As a result any of the photo detectors output equals OVDC when the trim is sensed The Proximity Sensor detects metallic objects without touching them e An inductive proximity sensor consists of a coil and ferrite core arrangement an oscillator and detector circuit and a solid state output The ferrite core and oscillator create a field generating out the front of the sensor When a metal object enters the field a loss in amplitude occurs The detector circuit recognizes the loss of ampli tude and generates OVDC to send to the PLC When the metal object leaves the sens ing area the sensor to returns to 24VDC and sends it to the PLC e As a result if a metal object is sensed the output of the sensor equals OVDC Refer to Figure 2 6 on page 8 for some examples of Sensors N Photo Eye Detector Proximity Detector Emitter and Receiver Senses metallic in one package objects FIGURE2 6 Examples of Sensor 2 8 KVAL 979 2 Operation Service Manual Quick Start Quick Start Note Before starting production it s recommended to perform a test cut on a board Follow the sa
54. rs or new operators Comprehensive lockout tagout KVAL 979 2 Operation Service Manual 1 11 Zero Energy to Start Up may use a gang box or other system to ensure that locks are secure and not removed without authorization Remember lockout tagout procedures work because you are the only one with the key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect 1 12 KVAL 979 2 Operation Service Manual Getting Help from KVAL Getting Help from KVAL Before you seek help first try the troubleshooting procedures Follow the procedures below If you are unable to resolve the problem 1 Locate the machine s Specification Plate and record the serial number 3 phase volts electrical print number and air print number Serial Number 3 phase volts Electrical Print Air Print 2 Contact our customer support team e In the U S and Canada call 800 553 5825 or fax 707 762 0485 e Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 e Email address is service kvalinc com e Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday On Line
55. st cylinders have an extend and retract port To adjust the extend motion of a cylinder you must adjust the flow control on the retract port this regulates the air flow exhausting from the cyl inder and the opposite is true for the retract motion 1 Check the air pressure to the machine 2 Check the flow controls to see that they are adjusted correctly and to the proper specifications 90 Degree Flow Controls Air How adjustiment screw Ti Restricted Air Flow Loosen Thumb tightening lock mut tefore aclustind Fir bey Sora Ajr Hose Connector Straight Flow Controls Air flow adjustment sera mol Uy posay Jas J a BEN 4 Wd IR Nt z s en Thumb thahiening beck mut Note The End that iS Balore adjusting AN nd Ser closest to the air flow n Free Flos In 3 Check for any obstructions to the cylinders such as Manual over screws or a misplaced tool etc FOLLOW ALL 4 ride button SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS 5 16 KVAL 979 2 Operation Service Manual Ca Troubleshooting the Air Cylinders 4 Check the solenoid air valves R Once activated The valve will allow full pressure to Caution cylinder Make sure you are clear of all moving parts a The solenoid valves can be manually operated by pushing the red manual override button on the end of the valve b If the valve seems to be leaking the seals may be dry or contaminated with water or it maybe that
56. stem environment temperature spacing contaminants etc 3 Call Kval customer support for a Return Material Authorization RMA When you call e Have the packing slip or invoice numbers available e Have the documented reason for return available 4 Send the merchandise back to Kval e Make sure the item s you are returning are securely packaged and well protected from shipping damage e Include the packing slip or invoice numbers e Include the documented reason for return e Include the RMA number with the parts package 1 14 KVAL 979 2 Operation Service Manual Getting Help from KVAL Page Intentionally Left Blank KVAL 979 2 Operation Service Manual Safety Sign Off Sheet Safety Sign Off Sheet Machine Model Number A Note to the Operator This machine can help you be highly productive only f you understand how to use t properly and follow the safe operating practices described in this document and the machine s manual If you do not understand the machine s proper operation or ignore the safe operating practices this machine can hurt or kill you It s in your best interest to safely and properly operate this machine Personnel Safety Concerns e have been properly trained in the operation of this machine e will always wear ear protection when operating this machine e I will always wear eye protection when operating this machine will never wear loose clothing or gloves when o
57. taluma Boulevard South Petaluma CA 94952 e Phone and Fax In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 e Business hours Technical Support 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday Parts amp Service Sales 6 30 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday Other sales related inquiries http www kvalinc com e Email service kvalinc com KVAL 990 HB Operation Manual KVAL 990 H Operation Manual Your Feedback is Welcome To help us design products that make your job easier and your business more successful we d like to gain your perspective about your user experience with our product that is the manual the machinery the software etc What was easy or difficult to use or to learn If you could change something about the design what would it be Please email your comments and suggestions for improve ment to userexperience kvalinc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information above Thank you http www kvalinc com KVAL 990 HB Operation Manual KVAL 990 HB Operation Manual Table of Contents Chapter1 Introduction to the 979 2 Miter Trim Saw System Ghapter 1 al a Glan Gissur 1 1 Overview of the 979
58. ter Receiver Emitter Receiver Emitter Receiver Machine in operation Breaking of any beam stops the machine 2 6 KVAL 979 2 Operation Service Manual Ca Operator s Tour Description of the Six Light Panel The six lights on this panel indicate the status of the 979 2 system The Sequence that the lights activate is as follows 1 Control Power 2 Overload Relay 3 E Stop 4 Stop 5 Start 6 24VDC Stop This light will be on if Machine Stop button is deac tivated Control Power light illuminates when the Control Transformer is pulled out and the power is working on secondary side of transformer o Start This light will be on once the Machine Start button is pressed and the ACR Relay is latched Overload Relay The overload circuit is working when light is on 24VDC light comes on once the E Stop The back gate is closed and Frame E stop is not acti ACR is latch and the vated when this light IS ON DAVDC power Supply is working KVAL 979 2 Operation Service Manual 2 7 Operator s Tour m About Sensors On the 979 2 sensors provide input to the PLC as part of the automation of the cutting process It is important to keep the sensors cleaned and aligned to keep the process running smoothly There are two classifications of sensors on the 979 2 Photo Electronic and Inductive Proximity Sen SOT The Photo Electronic Decor uses light as a t
59. the foot pedal and check the clamps for Lotk for Lock for accuracy without cutting the boards Machine Software Set Up In the ON position the setup mode is active the saws will be OFF In the OFF position the setup mode is not active and the Saws will be ON These keys may be taken out in the off position 2 18 KVAL 979 2 Operation Service Manual Description of User Interface Screens Main Screen The Main Screen is also the startup screen for the 979 2 From this screen all the basic user inter face controls are available to run a cut on a trim board DD 2s72 gt gt MEMME Stn im Mal ein 4 for START button Spry Haag D isabled Cut Length Quantity Machire Current Sern Pes ine FIGURE2 7 Main Screen KVAL 979 2 Operation Service Manual 2 19 Description of User Interface Screens About Home Machine Button O This button starts the home sequence on the machine which causes the movable fence to slowly scan to find a physical refer ence point on the frame When this point is found the position is stored and then used to calculate the location of all moves after this The home sequence must be performed every time the machine 1s powered up or reset Home Machine gt Reset Machine Button Reset If a fault occurs that cannot be cleared press the Reset Machine META TE button This button will reset the machine to the start position before homing
60. the menu selections for the 979 2 See Main Screen on page 2 19 ggg Manual a Fi See About the Manual Parameter Menu on page 2 21 Setup Modify Pre sets See About Calibration Data on page 2 22 an zum of 0 De FF E _ meruna To See Diagnostic Screen on page 2 28 See About the Preset Selection Button Group on page 2 20 KVAL 979 2 Operation Service Manual 2 17 Description of User Interface Screens Machine Feed Back Note Use this information to isolate issues if having problems with the machine At the top and at the bottom right hand corner of all user screens is status feedback information The information generated is as follows 1 General Machine Status This field lists the machine status through out the process status Waiting for START button Servo Head Disabled 2 Current Servo Positions This field shows the current position of the servo Current Servo Position About Lock Outs Option Store Program SET UP MOD ATORE OSRAM To allow the operator to make changes to parameters turn the 7 Set Up Lock to the On position When this key s in the Off position the parameters are locked out No changes to the parameters may be made in the off position Set Up Mode This setting allows technician to stop the saw from running if performing calibration on the machine The technician can feed in a trim board with
61. tion Service Manual 1 3 Safety First m Safety First This machine is a powerful electro mechanical motion control system You should test your motion system for safety under all potential conditions Failure to do so can result in dam age to equipment and or serious injury to personnel Safety Sheet Sign Off Sheet At the end of this chapter there is a safety sign off sheet It lists personnel and machine safety cri teria to understand before operating the machine It is highly recommended that personnel operat ing working on a machine meet the criteria listed in this sheet It is recommended the sheet be signed and kept for records See Safety Sign Off Sheet on page 1 16 Safety Terminology of Labels In addition to the nameplate KVAL machines may have other warning labels or decals that pro vide safety information to operators Safety labels should be clearly visible to the operator and must be replaced if missing damaged or illegible There are three types of warning labels or decals e DANGER means if the danger is not avoided it will cause death or serious injury e WARNING means if the warning is not heeded it can cause death or serious injury e CAUTION means if the precaution is not taken it may cause minor or moderate injury Safety Guidelines In addition to the caution and warning labels affixed to this machine follow the guidelines below to help ensure the safety of equipment and person
62. troller PLC3 2 R reset machine button description user interface2 20 return material authorization RMA 1 13 returning the product to Kvall 13 5 safety guidelines1 4 Safety Sign Off Sheet Safety Concerns1 16 sensors descriptions5 7 location on frame5 8 troubleshooing5 7 types2 8 voltage levels2 8 service connecting your machine to KVAL Service3 3 servo positions feedback2 18 setup screens2 22 six light panel description2 7 sequence list2 7 start light description5 14 start light description2 7 start machine button power up2 11 status light panel description5 10 use as troubleshooting key5 10 stop light description2 7 T tagout procedurel 8 troubleshooting air cylinders5 16 using status lights5 11 TwinCAT 2 software automation software3 2 U USB module3 2 user interface screens menu map2 17 V voltage levels KVAL 979 2 Operation Service Manual sensors2 8 WwW Windows CE operating system about3 2 Z zerk fittings4 4 locations4 4 zero energy start up clean up1 11 inspectl 11 KVAL 979 2 Operation Service Manual KVAL 979 2 Operation Service Manual
63. ual 5 9 Troubleshooting Electrical Problems AL 4 With the power off check for motor overloads by pressing each reset button usu ally at the bottom of the panel in SEQUENCE If one is tripped there will be a slight resistance to touch and a click sound as it is reset l Press Reset TTO sees Trip Indicator Test Thermal Overload Relay Check for Tripped Circuits 1 Remove lock and tag outs on the main power sources 2 Manually close disconnect sensors and energize the control circuit or transformer with its respective sensor Check the Status Light Panel If all lights are observed there are no overloads or emergency stops tripped See Troubleshooting with the Status Light Panel below for more information Note Most electrical problems are related to mechanical malfunction e g stuck motors jammed chain blocked photo sensors etc Note If a solenoid valve is suspected and not cleared in the air checks section see it can be electrically jumped to check operation Troubleshooting with the Status Light Panel The Status Light Panel is located on the Electrical Panel All six lights are illuminated when the system is in proper working order The lights turn on in a sequence and will stop at the point where a fault is first detected 5 10 KVAL 979 2 Operation Service Manual Ca Troubleshooting Electrical Problems The sequence that the lights turn on are as foll
64. user screen and return to the Windows desktop This can m 0 used if the operator needs to use a fe different Windows application FIGURE2 9 Manual Operation Screen KVAL 979 2 Operation Service Manual 2 27 Diagnostic Screen m Diagnostic Screen The Diagnostic screen displays all the tasks the 979 2 performs This screen can help with trouble shooting by associating the error code to machine sections or functions The top line will have the most current routine that is running If the machine issue can not be resolved call KVAL Inc 1 800 553 5825 Have any error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten down time CV o7r 2 2 _ I I TEZE Status Walting for START button Servo Head Disabled 2003 01 30 101000 AM Tankae Update Hunton Teni OO Ae in hp Clia KC pling iiei OOS Fei Cylinda MCplindes nihe TO ti Top Clamp C plier RE yl ndar baithi ES EHE Clamp Cynder KL lieder iied AALEN Feed Manager Feed Manage Initliced Op Kan few Eten Cylindes KCylinder Initfined GO Karl Sars hota Eilain oeir mit poet 01 016145 Haad Angle Cylinder KDC plindes inki AI ONE ep Saw Lotend Cylinder KCylinder beitlized Gt DE here ae Moor ontart Initliped tet flight Saw Manager Sane Manager Initliged CPOE eS hart Gar Ead Conde KC plindes niied Oe Kr ewe Motor a etl ped 013 0001 Head Angle Cyfinder KDC plindes initlired Sp S
65. ut Assisnnsa Press serie 2 27 About Manual Operation seer a a 2 28 Diae nose o eO Seesen E E 2 29 Operator s Tour m Operator s Tour This section takes you on a tour of the 979 2 Miter Trim Saw System machine Electrical Panel Operator s Station Left or Fixed Head In Feed Out Feed Safety Curtain Hopper Staging area and Feed In Foot Pedal Stop Feed Right or Movable Head Servo Motor and Ball Screw Safety Curtain FIGURE2 1 Identification of Key Assemblies of 979 2 2 2 KVAL 979 2 Operation Service Manual Ca Operator s Tour In Feed Section Dog Feed Moves product Operator Station through machine Foot Pedal E Stop Push to bG aai a shutdown machine utput to cylinaers in an emergency Air Input System Air Filter PSI Adjust and lubricator Hopper and Staging Area FIGURE2 2 Key Assemblies on the In Feed Section Foot Pedal The foot pedal controls the flow of the board through the machine e Press the right pedals to feed the product through the machine If the hopper is stacked the product will feed through automatically Or the quantity set on the main screen e Press the left pedal to stop the machine This acts like an E Stop KVAL 979 2 Operation Service Manual 2 3 Operator s Tour Operators Station The Operator Station contains a touch screen that allows communication between the operator and the machine Through
66. violation of any health or safety regulation STOP pro RCO Rest airt duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed safety guidelines are included in the operating instructions of this manual KVAL will be pleased to review with you any questions you may have regarding the safe operation of this machine Follow Your Company s Safety Procedures In addition to these safety guidelines Your company should have on site and machine specific safety proce oparsiors manuel bere GUTES to follow KVAL 979 2 Operation Service Manual 1 7 Safety First Lockout Tagout Procedure This policy is required by OSHA regulation 1910 147 and Cal OSHA S SB198 ruling of July 1991 Use the following lockout procedure to secure this machine while it is powered down During a lockout you disconnect all power and shut off the a r supply Be sure to use the tagout guidelines noted below To Lockout the This Machine 1 Assess the equipment to fully understand all energy sources multiple electrical sup plies air supply and pressure spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shut down 3 Obtain locks keys and tags from your employer s lockout center 4 Disconnect power a Turn the disconnect switches on the main electrical panel to the OFF position Then pull out the red t
67. y other cycle is a good rule of thumb The approved list of oil for lubricators is as fol lows e KVAL P N SYSLUBG e Chevron AW Hydraulic Oil 32 e G C lubricants light AW R amp O e Mobile DTE 24 e Shell Tellus32 e Gulf Harmony 32 To prime the lubricator find an air line on the carriage section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose Repeat this same procedure for the back section and other trouble areas It is recommended to check the lines every week to two weeks 4 6 KVAL 979 2 Operation Service Manual Ca Lubrication Points on the 979 2 Lubrication Points on the 979 2 This Section illustrates lubrication points on the machine See Maintenance Schedule on page 4 2 for types of lucubration and a schedule for preventive maintenance Lubrication Points Bottom of Machine FIGURE 4 15 Frame Lubrication Points KVAL 979 2 Operation Service Manual Lubrication Points on the 979 2 Lubrication Points Heads Fixed Head Movable Head Movable Head Bearings X4 Bottom Bearings X4 Bearings X4 __ FIGURE 4 16 Head Lubrication Points 4 8 KVAL 979 2 Operation Service Manual Ca Mechanical Adjustments Mechanical Adjustments The 979 2 is a powerful electro me
68. ystem ic e Moves the load Examples A motor or a pneumatic cylinder The Position Feedback e Provides location information to the controller Examples A limit switch a photo eye or ferrous eye a resolver or an encoder KVAL 979 2 Operation Service Manual 5 3 About Motion Control Typical Positioning Systems Common Contactor Control Unlike general purpose relays contactors are designed to be directly connected to high current load devices Contactors are designed to control and suppress the arc pro duced when interrupting heavy motor currents The figure below shows a block dia gram of a typical contactor circuit with typical voltages Should measure Should measure Line Control Voltage Control Voltage Voltage 24 VDC here 120 VAC here Power PLC Fuse s Output ON Relay Power Input Control Coil Contactor er VAC Input Power Output DC Control Circuit 7 Common Motor ON FIGURE 5 18 Common contactor Block diagram Should measure Line Voltage here Should measure Line Voltage here Should measure Line Voltage here 5 4 KVAL 979 2 Operation Service Manual About Motion Control Common Motor Drive Control An adjustable speed drive is used to control the motor speed and torque by varying motor input frequency and voltage A var able fr

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