Kval 777, Operation And Service Manual

Page 1: ...Innovation Quality Honesty Operation and Service Manual Published May 14 2019 777 Operation and Service Manual 777 Flat Back Bi Fold Machine ...

Page 2: ...egistered 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 D...

Page 3: ...r 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 T...

Page 4: ...KVAL 777 Operation Service Manual ...

Page 5: ... Start Maintenance 1 10 Post Maintenance Steps 1 10 Zero Energy to Start Up 1 11 Getting Help from KVAL 1 13 On Line Help 1 13 Product Return Procedure 1 13 Safety Sign Off Sheet 1 16 A Note to the Operator 1 16 Chapter 2 Operation of the 777 Kval 777 Process Summary 2 2 Powering Operations for the 777 2 3 How to Power Up the 777 2 3 How to Power Down the 777 2 4 Stabilizing Heads at the End of Sh...

Page 6: ...er 2 18 About the Hopper 2 19 Hopper Process 2 19 Controls 2 20 Main Control Box 2 20 Machine Control Box 2 21 Start Sequence Buttons 2 21 The 777 Main Electrical Panel 2 22 Description of the Six Light Panel 2 23 Chapter 3 Maintenance of the 777 Maintenance Schedule 3 2 300 Cycle Maintenance Steps 3 4 Clean Clean Clean 3 4 600 Cycle Maintenance Steps 3 5 Check Air Gauges and Inspect Water Traps 3...

Page 7: ...14 Lubrication Schedule 3 15 Typical Lubrication Kit 3 15 Lubrication Requirements 3 16 Pillow Block Bearing Housings 3 16 Flange Bearing Housings 3 17 Ball Rail Bearing 3 17 Pulley and Idler Shafts 3 18 Sample of Grease Locations for 777 3 19 Grease Locations on Frame of 777 3 19 Grease Locations 4 Shooter Bearings 3 21 Description of Air Input System 3 22 Air Input with Lubrication 3 22 Air Line...

Page 8: ...tic System Works 4 9 Important Notice about Adjusting Cylinder Speed 4 11 Adjusting Cylinder Extend Speed 4 12 Adjusting Cylinder Retraction Speed 4 12 Using Sensors to Trouble Shoot 4 13 Troubleshooting Electrical Problems 4 14 If the Power Stops During Normal Operation 4 14 Troubleshooting with the Status Light Panel 4 16 ...

Page 9: ...eral description and a table of available options page 1 2 Safety First IMPORTANT safety information is described in this section page 1 4 Lockout Tagout Guidelines Procedures describing Lockout Tagout page 1 8 Zero Energy to Start Up Procedure to power up your machine for the first time page 1 11 Getting Help from KVAL This section describes the method to contact the KVAL service center for help ...

Page 10: ...machine and clamping them Hinges can be placed in machine during cycle operation so they are in position when machine is actuated Four drills move in to drill for pivot hardware Hinges are manually placed and screws are auto matically dispensed to attach hinges simultaneously The machine then releases the doors and another operator removes them manually from the off feed side Factory service trip ...

Page 11: ...ser interface The Troubleshooting and Maintenance sections are directed toward qualified ser vice technicians only Operation Service Manual includes the following Chapter Description Chapter 1 Introduction Descriptions of Machine Line and Safety Information Chapter 2 Operation Interface Descriptions of how to power machine line and operator interface user screens Chapter 3 Title Information about ...

Page 12: ...ogy 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 DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if t...

Page 13: ...s at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before performing any mainte nance or repairs on this m...

Page 14: ...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 Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out the electrical and air pressure systems This shoul...

Page 15: ...chine is in violation of any health or safety regulation STOP pro 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 P...

Page 16: ...k and tag on each disconnect Only each operator may remove their own lock and tag 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 P Process shutdown R Recognize energy type electrical pneumatic mechanical etc O OFF Shut off all power sources and isolating devices P Place l...

Page 17: ...e spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shutdown 3 Obtain locks keys and tags from your employer s lockout center Lockout Tagout Power 4 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to pop...

Page 18: ...nance or repairs may started Post Maintenance Steps 9 After maintenance is 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 10 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe cond...

Page 19: ...lly 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 co...

Page 20: ...he 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 ...

Page 21: ...gh Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday On Line 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 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 ...

Page 22: ...e modified and how With what equipment is the unit interfaced What was the application What was the system environment temperature spacing contaminants etc 3 Call Kval customer support for a Return Material Authorization RMA When you call Have the packing slip or invoice numbers available Have the documented reason for return available 4 Send the merchandise back to Kval Make sure the item s you a...

Page 23: ...Getting Help from KVAL 1 15 KVAL 777 Operation Service Manual Page Intentionally Left Blank ...

Page 24: ...ollow my company s safety procedures I have read and understand these guidelines Machine Safety Concerns 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 I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the electr...

Page 25: ...tion of the machine page 2 2 Powering Operations Descriptions of power up power down homing and emergency stops page 2 3 Quick Start Steps to process a door page 2 7 Set the Width to the Door How to set the machine to match the width of a door page 2 9 Adjust for the Length of Door How to set the machine to match the length of a door page 2 13 Tour of the Machine Descriptions of the main assemblie...

Page 26: ...ervice Manual 2 2 Kval 777 Process Summary Turn Power ON Pull Out Control Transformer Push in Start Machine Pre Set a Load Doors b Set Width Buttons a Load Hinges b Push the Hinges Loaded Button Push Both Start Sequence Buttons Sequence Completed ...

Page 27: ...pplied to machine and main air supply is turned on Check that all E Stop buttons are out and safety gate door s are closed 1 Make sure the Electrical Disconnect the electrical cabinet is turned to the ON position 2 Pull out the green Control Transformer switch to the ON position 3 Push the green Start Machine button to boot up the machine Control Transformer Pull to ON Press Start 4 All lights on ...

Page 28: ...es from electrical storms Stabilizing Heads at the End of Shift At the end of the shift the Heads will slowly descend without air applied Before that occurs insert the pins to keep the Heads upright End of Shift 1 Keep air on 2 Remove pins from staging area at the end of the machine 3 Insert pins into each location near the side of each head 4 Flip the locking hook over the pins for each Head 5 Tu...

Page 29: ...s will stop but power to the PLC and the Operator Station Screen will remain on To Resume Normal Operation after an E Stop If an E Stop is activated use the following procedure to recover after the cause of the emergency stop is resolved 1 De activate the E Stop switch by pulling it out 2 Push the START MACHINE button on the operator s station 3 Other Safety Controls Other safety controls can incl...

Page 30: ...ng row of synchronized photo detectors that read the signal the emitter When the signal is blocked of any field 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 Emitter Receiver Emitter Receiver Machine...

Page 31: ...age 2 9 Power up the 777 See How to Power Up the 777 on page 2 3 Turn ON Drills Turn ON Screw Drop Turn ON Screw Drivers Reverse Screw Drivers OFF Set Door Length Stops must be moved when switching between door lengths See Adjust for the Length of a Door on page 2 13 See Powering Operations for the 777 on page 2 3 Attach the Hinges knuckles side up to each Hinge Applicator Adjust the width of the ...

Page 32: ...ol panel Reset the alignment Press Unclamp Button again to clamp See Controls on page 2 20 Push the Hinges Loaded Button the Hinge Applicator will turn 180 and place he hinges over the gap of the doors Push the Start Sequence Buttons at the same time The Heads lower and attach the hinges to the door The machine will unclamp automatically and feed the door out Repeat process for next door Quick Sta...

Page 33: ...g width adjust but tons on the Main Controls and a tape measure on the side of the machine 1 Note the width of the doors to be pro cessed 2 While observing the tape measure located on the side of the machine open or close the width assembly of the machine 3 Line up the arrow to the desired width 4 Begin processing the doors Locater Arrow FIGURE 2 3 How to Set the Width ...

Page 34: ...izes pitches can cause uneven application of the hinge Hopper Gate Assembly Screw Tracking Plate Assembly Hopper Cylinder Screw Delivery Tubes Air Injected Not seen Plastic tubes that deliver screws to the Hinge Applicator Plate Assembly Cylinder Screw Pick Off Slide Hopper Process 1 Pour Screws into the Hopper 2 The Hopper moves up and down periodically during the process by the Hopper Cyl inders...

Page 35: ... needed Adjustments may be needed for top and bottom drill locations Forward Limit Switch Indicates drill is at door drill ing Back Limit Switch Indicates assembly id ready to drill Drill Height Adjust Adjusts the center location of the hole on different thickness doors 8 0 to 6 8 Door Adjust Slide Drill Assembly to desired door length FIGURE 2 4 Drill Pre Set Locations ...

Page 36: ... Get tool that is located on the side of the machine 4 Loosen set screw and use handle to ratchet the drill to the correct height 1 2 the doors width Note A line is scribed to indicate normal door widths Move until the arrow meets that scribe 5 Repeat for other three drills 6 Re attach the cover 7 Reverse Lockout Tagout 8 Process doors Note Adjust All 4 Drills Loosen and move to desired location R...

Page 37: ...th of a Door There are some mechanical adjustments to match the length of an 8 0 or 6 8 door Adjust both Door Stops Adjust all 4 Drill Assemblies Automatic Adjustment of Heads 8 0 to 6 8 Door Adjust Slide Drill Assembly to desired door length Stop Stop FIGURE 2 5 Length Assemblies to Adjust ...

Page 38: ... 4 With a 1 2 wrench loosen the bolt Do not remove 5 Slide the assembly to the desired collar 6 Re tighten the bolt 7 Repeat for other three drills 8 Reattach the cover 9 Reverse Lockout Tagout 10 Process doors Note Adjust All 4 Drills Note In this sample we are moving to the 8 0 door position Reverse steps to return to 6 8 posi tion 6 8 Reference 8 0 Reference Loosen Bolt Slide to Reference Colla...

Page 39: ...Procedure on page 1 9 2 For the Right Hand Stop unbolt the 4 bolts and move to the marked location 3 For the Left Hand Stop unbolt the 2 bolts and move to the marked location 4 Secure all bolts 5 Reverse Lockout Tagout 6 Process doors See photos below for the stop locations Right Hand Stop align the rear edge of the plate to the mark Left Hand Stop align the front edge of the plate to the mark 6 8...

Page 40: ...are adjusted by setting the switch at the Main Control Panel 8 0 Location 8 0 Location 6 8 Location Switch to the desired length of door 8 0 Doors The two outside Heads will move to towards the ends of the machine 6 8 Doors The two outside Heads will move towards the center of the machine The middle Head remains stationary ...

Page 41: ...Machine Control Hinges Loaded Unclamp Pause and E Stop Top Hole Drill X4 Drills holes on the top and bottom edges of the doors Start Sequence Push both buttons at the same time to begin pro cess Air Manifold Solenoids to drive air assemblies Rear View Feed Motor Moves door out of the machine Width Adjust Motor Push both buttons at the same time to begin the process Screw Driver Motor X3 Drives scr...

Page 42: ...nother operator removes them manually from the off feed side shooter 4 Shooter Hopper Gate Assembly Screw Tracking Plate Assembly Hopper Cylinder Screw Delivery Tubes Air Injected Not seen Plastic tubes that deliver screws to the Hinge Applicator Screw Motor Plate Assembly Cylinder Screw Pick Off Slide Screw Drivers Hinge Applicator Split Shells X4 Receives 4 screws straight ens and aligns them Sc...

Page 43: ...izes pitches can cause uneven application of the hinge Hopper Gate Assembly Screw Tracking Plate Assembly Hopper Cylinder Screw Delivery Tubes Air Injected Not seen Plastic tubes that deliver screws to the Hinge Applicator Plate Assembly Cylinder Screw Pick Off Slide Hopper Process 1 Pour Screws into the Hopper 2 The Hopper moves up and down periodically during the process by the Hopper Cyl inders...

Page 44: ...the screws from dropping to the Hinge Applicator Drills 1 3 This button powers the side drills ON or OFF Reverse Screw Drivers Reverse the rotation of the screw drivers Use this button to back out screws improp erly set into doors Machine Power Press Start to get the machine ready to process Press Stop to end the process Control Circuit Turns machine power ON or OFF Width Adjust Push to set the wi...

Page 45: ... loaded into the Hinge Applicator press the button The appli cator will flip into attachment position Unclamp Press to unclamp the door May be used to straighten a door in process Emergency Stop If safety issues occur press this button Removes power from the entire machine Clear Screws If screws get stuck in the deliv ering process press to blow the screws out of the loading assembly Start Sequenc...

Page 46: ...blies in the panel Warning High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off If working on the panel follow safety protocol as described in Chapter 1 PLC and Power Supply Input Output Terminals 110 V 24 V Terminals High Voltage Section Fuses Contactors and Control Transformer VFDs Width adjust and Feed ...

Page 47: ...ht illuminates when the Control Transformer is pulled out and the power is working on secondary side of transformer Overload Relay The overload circuit is working when light is on E Stop The back gate is closed and Frame E stop is not acti vated when this light is on 24VDC light comes on once the ACR is latch and the 24VDC power Supply is working Stop This light will be on if Machine Stop button i...

Page 48: ...Description of the Six Light Panel KVAL 777 Operation Service Manual 2 24 ...

Page 49: ...oduction process Chapter 3 at a Glance Section Name Summary Page Maintenance Schedule This section describes the assemblies to sched ule for maintenance Daily Weekly 5 Six Month Checkups page 3 2 Lubrication Requirements This section describes the lubrication require ments for the machine including types of lube to use This section includes Linear Bearings Flange Bearing and Pillow Blocks Gear Mot...

Page 50: ...o all machines Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tagout or lockout the electrical and air pressure systems This should be done in accor dance with applicable state and or federal code requirements To view a video of the maintenance process visit the KVAL website Select the Video Tab to view videos http www kvalinc com 300 Cycles...

Page 51: ...e Lubrication Schedule on page 3 15 Clean Clean all bearing shafts with clean dry cloth 12 000 Cycles Inspect Inspect chains for proper tension or damage Inspect Inspect all air cylinders for air leaks Replace if seal is leaking Inspect Inspect hydraulic lines for loose fittings leaks and cracks Inspect Inspect ball rail shafts for pitting or abrasions Lubricate Clean and lubricate all slides and ...

Page 52: ...lean Clean Sawdust and grime build up can cause issues with the operation of the machine Use pressured air to blow off dust and debris on entire machine Use a clean rag to clean areas not affected by pressurized air Also blow out any dust collection units Check vertical bearings for loose screws Loose screws could cause bearing damage ...

Page 53: ... Inspect Water Traps Air Pressure Gages Adjust if nec essary to the proper PSI located on the label Adjust only if Trained in Maintenance Inspect Air Filter Water Traps Empty trap if necessary Slide locking switch down to unlock twist trap to remove Reverse action when installing trap Inspect Tooling Inspect the Tooling for wear Screw Driver Bits ...

Page 54: ...L 777 Operation Service Manual 3 6 Lubricate inside of Hopper Lubricate the inside of the Hoppers with a light coat of dry silicone spray Lubricate the input to the screw drop hoses Provides an easier screw drop Do not over spray oil ...

Page 55: ...heck for looseness A rule of thumb is to pull belt if belt moves too freely then replace belt Belts can become slick from use lesson ing traction on door Check belts for slickness or door slippage Inspect Screw Drop Tubes on 4 Shooter Inspect screw drop tubes for kinks cracks wear from rubbing Ensure tube clamps are tight Inspect all Photo Eyes Inspect all photo eyes secure and tight Check Connect...

Page 56: ...king sound when moved to the extreme Note Depending on the model of limit switch the amount of pre travel amount of movement from the arms resting position is either 5 or 20 degrees before the limit switch actuates Inspect Screw Receiver Parts Inspect screw receiver parts on six shooters for cracks or breaks Inspect 1 Screw Receiver 2 Spring 3 Split Shell 4 Steel Ring 5 Rubber Ring 6 Steel Ring Re...

Page 57: ...s assem blies air valves and hoses Check from source to end assembly Check Hoses for kinks and rubbing manifold connections and Air Cylinder connections Refill Lubricators Ensure Air is turned off Refill all lubricators Replace fluid if milky or discolored Use ab ISO 32 stan dard hydraulic oil KVAL PN SYS LUBEG Slide locking switch down twist bowl and remove Refill bowl Reverse action when install...

Page 58: ...ngs Grease ball screw bearings if applicable For a table of lubrication types to use Lubrication Schedule For locations to lubricate See Grease Ball Screw Bearings Clean Bearing Shafts Clean all bearing shafts with clean dry cloth Spray shaft with silicone oil and clean build up grime and dirt ...

Page 59: ...ns can stretch over time of use Check for chain stiffness Stiff chains do not provide a tight fit over the gears Inspect Air Cylinders Inspect all air cylinders for air leaks Replace the cylinder if seal is leaking Symptoms include a cylinder not extracting or retracting to the limits Cylinders not holding their position Inspect Ball Rail Shafts and Ball Screws Inspect ball rail shafts for pitting...

Page 60: ... 12 Clean and Lubricate Slides Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray Clean Inside Hopper Clean inside hopper with dry sili cone oil and a 3M ScotchBrite pad or equivalent Wipe dry with a clean dry rag ...

Page 61: ...ropriate tool to verify that the hardware is tight Electrical Check all connections in each node box and electrical panel Wires may become loose due to vibration Check contactors for wear Wash Filter and Lubricator Bowls Wash filter and lubricator bowls with soapy water Slide lock down to unlock Twist bowl to remove it Remove filter from Air filter assembly Inspect and clean or replace if necessar...

Page 62: ...ling Note Depending on Machine or Option some of these tools may vary Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tagout or lockout the electrical and air pressure systems This should be done in accor dance with applicable state and or federal code requirements 4 Shooter Tooling Screwdriver Bits 1 500 cycles Steel Rings 7 500 cycles Rubbe...

Page 63: ...w Block Bearing Flange Block Bearing Idler Shafts Pulley Monthly 4 Shooter Bearings One Pump 4 Times a Year Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Note Some CNC Machines drop every 5 10 cycles Either lubricant listed below is approved to use KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32...

Page 64: ...rface of the fitting so that it can be wiped clean to reduce the amount of debris carried with the grease into the bearing Note Bearings without grease fittings have been pre lubri cated at the factory and do not require further lubrica tion Note Clean excess grease to avoid contact with feed belts clamping areas or the door Zerk Fitting Pillow Block Bearing Housings A pillow block is any mounted ...

Page 65: ...r reliable operation Greasing Flange Bear ing Bearing Housings Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 250 hours of operation Lip FIGURE 3 7 Flange Bearings Ball Rail Bearing Ball Rail Bearings are linear bearings that are attached to positioning rails In most cases the bear ings are attached to assemblies to move them in the X Y or Z direction ...

Page 66: ...ntains an idler shaft that has a zerk fitting to apply grease An opening in the idler shaft dispenses grease to the inner diameter of the pulley Pulley in Action Breakout of Pulley Assembly Grease IN Grease Out Note It is important not to overfill the Idler Shaft Avoid getting excess grease on the belts Idler Shaft Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube E...

Page 67: ...person nel Shutdown the machine and follow the Lock Out Tag Out procedures Caution Grease Locations on Frame of 777 Identify zerk fittings and apply EP 2 grease Use an extender to reach tight areas Make sure to Lockout Tagout before maintenance For recommended greasing schedule see Lubrication Schedule on page 3 15 Pillow Block Hub Style Feed Motor assembly Pillow Block Hub Style Width adjust asse...

Page 68: ...r to reach tight areas Make sure to Lockout Tagout before maintenance For recommended greasing schedule see Lubrication Schedule on page 3 15 Head Vertical Axis Moves the entire head assembly in the Vertical direction 2 rails 2 bearings per rail Head X Axis Moves the entire head assembly in the X axis direction 2 rails 2 bearings per rail FIGURE 3 10 Head ...

Page 69: ...s and apply EP 2 grease Use an extender to reach tight areas Make sure to Lockout Tagout before maintenance For recommended greasing schedule see Lubrication Schedule on page 3 15 Note Do not overfill Grease may drip down to door Gear Zerk Fittings Recommended One Pump 4 Times a Year 14 Bearings Total FIGURE 3 11 Front View of Head ...

Page 70: ...delivers the lubricated air to valve banks and air cylinders Shop Air Input Air On Off Knob Muffler Filter purge Pressure Gauge with adjust Clean Dry Air CDA to Air Blow Off Lubricator Lubricated Air Output FIGURE 3 12 Typical Air Line Filter and Lubrication System 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 o...

Page 71: ...f 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 che...

Page 72: ... bit push the bit holder see images back toward the Four Shooter assembly and hold pull bit out of holder 2 To insert screwdriver bit reverse step 5 above push bit holder back toward Six Shooter assembly and hold while inserting new bit Release holder to secure bit Remove Driver Bits Bit Holder Lock Bit Slide Bit Holder lock Back Slide Bit Out ...

Page 73: ... 4 at a Glance Section Name Summary Page About Contactor Control This section contains basic information on the operation about contactors page 1 2 About Typical VFD Drives This section contains basic information on the operation about VFD s page 1 4 About Pneumatic Control Includes procedure to trouble shoot air cylinders such as adjusting extension and retraction speed page 1 7 Using Sensors to ...

Page 74: ...e may cause personnel injury or death Troubleshooting checks must be performed by a Qualified Electrical Technician PLC Output Fuse s Line Voltage Power Contactor Control Coil Input Power Input Power Output Control Circuit Common ON Should measure Control Voltage 120 VAC here Should measure Line Voltage here Should measure Line Voltage here Line Voltage here Should measure Relay 120 VAC DC Should ...

Page 75: ...as a trigger to check the circuit See Troubleshooting with the Status Light Panel on page 1 16 1 Open the Main Electrical Cabinet to find the Contactor Thermal Overload Assem bly 2 Press each Green Reset button on the Thermal Overload An audible click will be heard on the tripped circuit Take note of tripped circuit 3 Once the overloads are reset verify LED s are on 4 Rerun the machine and verify ...

Page 76: ...hooting checks must be performed by a Qualified Electrical Technician Common Motor Drive Control PLC Output Fuse s Line Voltage Motor Power Motor Power Input Output Power Control Circuit Common ON Measure Control Voltage 24 VDC here Measure Line Voltage here Measure Line Voltage here ON Drive STF Forward RL STR Revers 2 SD COMMON OFF OFF OFF Run 300 Run Light should be ON Displays the Motor Freque...

Page 77: ... diagram see Figure 1 3 on page 1 4 VFD models vary in KVAL machines depending on where it is used voltage requirements and type of PLC used This is a general view on the VFD See the machine s Electrical Print for detailed information Line Voltage IN Converted Signal OUT to Motor Operation Panel Access to manual operation VFD This panel can be used for trouble shooting purposes Fault Errors will b...

Page 78: ...e lit To reset a VFD 1 Push lighted button to reset the indicated motor b If the button light turns off continue with production c If the button stays lit identify the motor by way of the label on the button turn off that function at the switch panel Check the corresponding output on the PLC output If the output is on it will not let the motor reset Dis connect the output wire and verify that the ...

Page 79: ...re Air Cylinder Common Control Circuit ON Measure 24 VDC here Control Voltage Should have High Pressure air here Cylinder Control Control Coil Input Air Input Air Output Valve Should have High Pressure air on Activated Output Schematic Drawing of Pneumatic Circuit Note Pre 2006 machines may not contain the 24 Volt relay 120 Vac is directly fed into the Control Coil Check the input circuitry to the...

Page 80: ...ut 24V from PLC to open a port FIGURE 1 7 Typical Pneumatic Assembly About the Coil Solenoid The Solenoids are connected to the top of the manifold Labels indicating their function and PLC connections are attached to the solenoid body Use this information to troubleshoot system if nec essary Solenoid type will vary with machine application Common controls include an operational LED and Manual oper...

Page 81: ... delivered to port B FIGURE 1 9 Cross section of Air Cylinder How the Pneumatic System Works The Pneumatic system consists of a brain PLC an action Positioning System and a result Moving the Load For a generalized representative this section describes the process to move a router to the extend and the retract position with a double valve Extend Process If PLC determines the conditions are right to...

Page 82: ... V Applied Router Assembly Load Position Feed Back Air In Control Valve Extend Sen sor Acti vated Air Pressure Extends Cyl inder and Router Assem bly EXTENDED Retract Process If the PLC determines the conditions are right to retract the Router 1 The Control Valve directs compressed air to the retract port of the Cylinder 2 The Cylinder and Router retract deactivating the Extend Sensor 3 When the C...

Page 83: ... Notice about Adjusting Cylinder Speed Do not adjust the cylinders to speed up production The air cylinder timing is part of a well tuned system of electronics programming and mechanics Adjustment of the cylinders for speed can cause unsatisfactory results in feed and out feed problems far marks in the corners of hinge pockets and flipping screws in Hoppers However sometimes machine settling mecha...

Page 84: ...tion Service Manual 1 12 Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Tip If Installing a new flow control assembly shut down the flow control and back out 4 to 5 turns this position is a good starting point for kine adjust ...

Page 85: ...en get dirty Make sure they are clean If they are not clean debris may block the signal or provide a false signal Check output voltages of the sensors in the active mode The voltage should effec tively equal 0 VDC Check the output voltages of the sensors in inactive mode The voltage should effec tively equal 24 VDC ...

Page 86: ...t 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 system 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 respe...

Page 87: ...e panel in SEQUENCE If one is tripped there will be a slight resistance to touch and a click sound as it is reset Trip Indicator Press Reset Thermal Overload Relay Test 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 ligh...

Page 88: ...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 1 17 STEP 2 Overload Relay Amber If light is OFF go to item B on page 1 18 STEP 3 E Stop Amber If ...

Page 89: ...e 120 VAC Terminal Strip 7 If there is no power between 1 and 2 check the secondary side of the trans former a Check between X1 and X2 If no power is measured it is a bad transformer b If there is power at X1 and X2 check the other side of the fuse If now power replace the fuse 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 s...

Page 90: ...k if 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 Stop Light OFF Check for 120 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 ...

Page 91: ...ut side for 120 VAC If no 120 VAC check the fuse If there is 120 VAC and no 24VDC replace the 24VDC Power Supply If there is 24VDC Reconnect the V wire 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 o...

Page 92: ...Troubleshooting with the Status Light Panel KVAL Operation Service Manual 1 20 ...

Page 93: ...rt Number LUBEKIT3 15 KVAL getting help1 13 L linear bearing maintenance schedule3 15 lockout and tagout Guidelines1 11 lockout procedure1 9 Lubrcation Schedule3 15 Lubrication Schedule Idler Shaft3 15 M machine2 4 O overload relay light description2 23 P pillow block bearing maintenance schedule3 15 power lock out procedure1 9 power up troubleshooting4 14 product return procedure1 13 R return mat...

Page 94: ...2 KVAL 777 Operation Service Manual T tagout procedure1 9 troubleshooting using status lights4 16 Z zerk fittings3 16 locations3 16 zero energy start up clean up1 11 inspect1 11 ...

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Page 96: ...partment Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL 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 Email service kvalinc com http www kvalinc com ...