Kval 994-X, Operation And Service Manual

Page 1: ...Innovation Quality Honesty Operation and Service Manual Published 11 20 2017 994 X Pre Hanging Door System 994 X Pre Hanging Door System ...

Page 2: ... 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 ...

Page 3: ...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 abov...

Page 4: ...KVAL 994 X Operation Service Manual ...

Page 5: ...Tagout 1 11 Lockout Tagout Power 1 11 Lockout Tagout Air Supply 1 12 Start Maintenance 1 12 Post Maintenance Steps 1 12 Zero Energy to Start Up 1 13 Getting Help from KVAL 1 15 On Line Help 1 15 Product Return Procedure 1 15 How to Download the Service Application 1 17 Download Application 1 17 Safety Sign Off Sheet 1 20 A Note to the Operator 1 20 Chapter 2 Operation of the 994 X Operator s Tour ...

Page 6: ...n 2 23 Opt BC Ball Catch Motors 2 24 Out Feed 2 25 Option O Air Blow Off 2 26 Option IL Left Hand Right Hand Door Indicator 2 26 About the Electrical Panels 2 27 Main Electrical Panel 2 27 High Frequency Panel 2 28 Description of the Six Light Panel 2 29 About Sensors 2 30 Quick Start 2 31 Powering Operations for the 994 X 2 33 How to Power Up the 994 X 2 33 Home the 994 X 2 34 How to Power Down t...

Page 7: ... Routine 3 6 Select Calibration 3 6 Select Door Parameters 3 6 Load the Door and Start the Cut 3 6 Check Specifications of the Front Section 3 7 Enter a Positive or Negative Number 3 7 General Instructions to Adjust Parameters 3 8 Step 1 Hinge Carriage Calibration 3 9 Step 2 Router Calibrations 3 12 Step 3 Pre Drill Calibration 3 13 Step 4 Option CH Chisel Calibration 3 15 Calibration of the Back ...

Page 8: ...ors 5 9 Grease Ball Screw Bearings 5 10 Clean Bearing Shafts 5 10 12 000 Cycle Maintenance Steps 5 11 Inspect Chains for Proper Tension 5 11 Inspect Air Cylinders 5 11 Inspect Hydraulic Lines 5 11 Inspect Ball Rail Shafts 5 12 Clean and Lubricate Slides Cylinder Rods and Bearing Shafts 5 12 Clean inside Hopper 5 12 72 000 Cycle Maintenance Steps 5 13 Inspect Nuts and Bolts 5 13 Check Door Feeding ...

Page 9: ...Heads 5 28 Chapter 6 Troubleshooting the 994 X About Motion Control 6 2 Basic Control Circuit 6 2 Typical Positioning Systems 6 4 Troubleshooting Basics 6 7 Before you Adjust 6 7 Analyze the Sub Systems 6 8 About a Typical Contactor Control 6 10 About Contactor Troubleshooting 6 11 About Typical VFD Motor Drive Control 6 12 About the VFD 6 13 About VFD Troubleshooting 6 14 About a Typical Pneumati...

Page 10: ...shooting Electrical Problems 6 25 If the Power Stops During Normal Operation 6 25 Troubleshooting with the Status Light Panel 6 26 Network System Overview 6 31 Connections to Servo Drives 6 32 Connections to VFD s High Freq Panel 6 33 Symptoms and Possible Causes 6 34 ...

Page 11: ...ral description and a table of available options Page 1 2 Safety IMPORTANT safety information is described in this section Page 1 6 Zero Energy to Start Up Procedure to power up your machine for the first time Page 1 13 Getting Help from KVAL This section describes the method to contact the KVAL service center for help The section includes how to get information from the speci fication plate tor p...

Page 12: ...mmed to drill all common hinge patterns automatically Additionally the use of servo motors allows you to machine both 1 4 and 5 8 radius corners without changing out tooling Hinges may be attached manually or with the optional Six Shooter to install 3 1 2 X 3 1 2 hinges or the optional Eight Shooter for attaching 4 X 4 hinges while the door and jamb remain clamped in position Door to door producti...

Page 13: ...ll bearing equipped steel wheels is mounted on an overhead track that is precisely aligned to ensure the hinge is properly position into the pocket at each hinge location Option AC Metal Door Sensing Proximity Switch Allows operator to do the edge prep on a steel door without acciden tally doing a face bore into the door Option BC Ball Catch Drills Drill assemblies are mounted onto the lock boring...

Page 14: ...orner Squaring The 994 X system combines very high quality hardware detailing with high speed productivity Unique features include computer con trolled ball screw movements for all router and chisels complete with square lock face plates Backsection will have the ability to machine a face plate at both 0 and 3 degree Operator can select widths from 1 to 1 1 4 wide and up to 2 3 4 in length Option ...

Page 15: ...ow Door Support Supports doors between 12 16 Structure utilizes air cylinders and 7 pairs of industrial wheels for sup port mechanism is automatically put in and out of position via a selection Split Jamb Staplers Two 1 4 crown staple guns are mounted onto the jamb clamp brack ets While clamped in the machine staples will be driven into the back side of the split jamb to keep the male and female t...

Page 16: ...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 17: ... 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 ma...

Page 18: ...epairs 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 should...

Page 19: ...hine 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 Pr...

Page 20: ...ock 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...

Page 21: ...re 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 po...

Page 22: ...enance 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 con...

Page 23: ...ally 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 c...

Page 24: ...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 ...

Page 25: ...ugh 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 26: ...re 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 ...

Page 27: ... com 2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Googl...

Page 28: ...d Enter your name The KVAL tech nician will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connec tion to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support App is loaded and completed call the KVAL service center 1 800 553 5825 and h...

Page 29: ...How to Download the Service Application 1 19 KVAL 994 X Operation Service Manual Page Intentionally Left Blank ...

Page 30: ...follow 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 elect...

Page 31: ...Safety Sign Off Sheet 1 21 KVAL 994 X Operation Service Manual ...

Page 32: ...Safety Sign Off Sheet KVAL 994 X Operation Service Manual 1 22 ...

Page 33: ... to calibrate the machine and process a door Chapter 2 at a Glance TABLE 2 3 Section Name Summary Page Operator s Tour Descriptions of the operation of the parts and assemblies of the machine Page 2 2 Quick Start A summary of the steps to machine a door Page 2 31 Powering Operations Descriptions of power up power down homing and emergency stops Page 2 33 Description of the User Interface Screen De...

Page 34: ...jamb clamp secures the jamb to hold it in place as routing and drilling occur Door Stop The door stop sets the door in the correct position during in feed Jamb Stop The jamb stop acts as a jamb placement guide when jamb is being loaded Door Clamp Pedal The door clamp pedal is a foot pedal that when pressed activates the door clamp to either clamp or unclamp the door Jamb Clamp Pedal The jamb clamp...

Page 35: ... Router Option RC see Page 2 13 In Feed Out Feed Front Section Hopper Back Section Hinge Carriage 1 Six Shooter Valve Bank 2 Valve Bank 1 Lock Plate Assembly Electrical Panel 2 Electrical Panel 1 Hydraulic System 6 Shooter Valve Bank 3 Air Input Fil ter Lubricator Lock Bore Assembly Hinge Carriage 2 Hinge Carriage 3 Hinge Carriage 4 Opt BC Ball Catch Motor X2 Opt K Eight Shooter Hydraulic System 8...

Page 36: ...ents Above are exam ples of an Op Station attached to the machine and a centrally located station with a Handler interface Controls Emergency Stop Start boot up and Stop Lock Out ability to change programs Turn ON or OFF Control Transformer FIGURE 2 2 Operators Station with touch Screen Interface Machine Control The machine control is located is centrally located for easy access The control works ...

Page 37: ...nd manual modes Door Clamp Push the Door Clamp foot pedal clamp and then un clamps the door after each cycle of operation when the machine is in the manual mode Press once to clamp and press again to un clamp Jamb Clamps Two Clamps per Head Manually clamped Door Clamps Two Clamps per Head Can be Auto clamped and Manually clamped Jamb Ledge Jamb Stop Door Clamps Jamb Ledge Jamb Stop Jamb Clamp FIGU...

Page 38: ...hem In Feed System Door Enters Machine here Sensors triggered and width is adjusted to door Hydraulic Tank for 8 Shooter Sets and Lifts Eight Shooter out of Hinge pocket Feed Motor Drives the Door through the machine Door Stops Opt N Weather Strip Brackets Keeps weather strip on jamb away from machining process Not shown See Opt N Weather Strip Brackets on page 2 7 Door Input Feed Belt Drives the ...

Page 39: ...om of Door Right Hand Top Door Left Hand 8 0 6 8 Some Options may have a separate 7 0 stop in between the 8 0 and 6 8 stops Some options use the 6 8 stop as a reference for the 7 0 door 6 8 8 0 FIGURE 2 6 Stops Located on Machine Opt N Weather Strip Brackets Isolates Weather Strips during the routing process A protective bar across top of H block keeps the strip up and away from the routers Protec...

Page 40: ...upport Machine Control Hinge Carriages 1 through 4 Hinge Carriage 1 Hinge Carriage 2 Hinge Carriage 3 Hinge Carriage 4 Six Shooter Opt Z Quick Change Machine Control Opt K Eight Shooter Opt V Narrow Door Support Supports Doors under 16 0 for either Hinge or Lock Side Standard Pre Drill Router Opt CR adds CR Router Opt CH adds Chisels 4 corners FIGURE 2 7 View of Front Section ...

Page 41: ... depth Each standard hinge routing section is equipped with two 1 1 2 HP High Fre quency spindle motors one for routing and one for pre drilling on both the door and jamb Opt CR adds another spindle motor for a Counter Rotate Router Servo motors allow the hinge router to accelerate out of and decelerate into hinge cor ners eliminating over travel Changeover from 3 1 2 to 4 hinges is accomplished b...

Page 42: ...Drill Opt CR Counter Rotate Router Standard Router Retract Extend Cylin ders FIGURE 2 8 Hinge Carriage Parts with added Option CR Option CH Added Chisels This option adds chisels to each head The chisel assemblies have an upper and lower chisel to square off the jamb and door pockets Pre Drill Opt CR Counter Rotate Router Standard Router Opt CH Chisel Left Opt CH Chisel Right FIGURE 2 9 Hinge Carr...

Page 43: ...at is interlocked with a safety switch to disable the staple guns unless there is a jamb clamped in the machine Staplers For full process information see Quick Start on page 2 31 To Use this Function 1 Enable by selecting the Split Jamb Stapler enable dis able button 2 If not already done so load the male split jamb into the female slot of the jamb 3 Load jamb assembly into machine 4 During proces...

Page 44: ...of the six shooter 3 The Six Eight Shooter is mounted on an overhead track that is precisely aligned to ensure the hinge is properly position into the pocket at each hinge location 4 The operator a places a hinge to the magnetic indexing fixture b rolls the Six Eight Shooter over to the hinge location and pivots it into the H block c drives all six screws into the door and jamb d press the Reset s...

Page 45: ...eight shooter attaches a 4X4 hinge and has 2 Hoppers to deliver screws Eight Shooter Six Shooter The Six Shooter attaches 3 screws to the jamb and 3 screws to the door Hoppers Supplies screws to Jamb and Door Indexing Fixture Magnetic Aligns screws and attaches the hinge to the door and jamb The Eight shooter attaches 4 screws to the jamb and 4 to the door Eight Shooter Magnetic Indexing Fixture 4...

Page 46: ...ushroom button Start Sequence The start sequence drops the Six Shooter into the pocket while starting motor for hydraulics It also drops the screws down aided with air injection if equipped to speed the screw feed process Hopper Slide Valve The hopper slide valve provides the operator a remote air shut off that controls air flow to the screw hopper to aid in un jamming debris in the screw drop zon...

Page 47: ...e operation of the Six Shooter If you think problems are being caused by the cylinders please contact the KVAL Service Department for direction Important Do not put Magnetized Screws in Hopper Magne tized screws can cause sluggish response to screws getting stuck Hopper plates could get magnetized and will have to be demagnetized with a degausser Hopper Opt Z Quick Change Dump Gate Opt Z Quick Cha...

Page 48: ...ir injectors to speed the delivery to the Screw Receiver Tubes Quick Change Process Some Six Shooter Systems have an a quick change option to quickly change to differ ent colored screws To start the quick change process 1 Park the Six Shooter 2 Press the Load Unload button on the Six Shooter panel The back section of the Hopper will cycle upward once to shift all the screws from the back door to c...

Page 49: ... hinge Screw Receiver Tubes These tubes receive the screws from the hopper by way of plastic tubes Latch Arm Latches to H Block to secure in place Latch Arm Cylinder Moves latch arm in and out of position Hydraulic Motor Gearbox Geared to drive 6 screws simultane ously Chucks X6 Holds 6 screws aligned to the Door and the Jamb Hinge Applicator Location to attach Hinge Turret to Adjust Depth Adjusta...

Page 50: ...n knuckle sizes is 1 second A switch that is located on the 8 shooter hinge applicator triggers a solenoid to retract to provide space for the wide spring hinge Solenoid Retracts to provide space for a wide spring knuckle hinge Hinge Applicator Switch to trigger solenoid To Use this Function Flip the switch to activate the Solenoid Place the wide knuckle hinge into the Hinge Appli cator See Quick ...

Page 51: ...d steel wheels and is mounted on an overhead track The track and the Six Shooter are precisely aligned to ensure the hinge is properly positioned into the pocket at each hinge location Opt K Eight Shooter Keep 6 Shooter in park and move the shooter down the machine Six Shooter Keep 8 Shooter in park and move the shooter down the machine FIGURE 2 15 Over Head Track ...

Page 52: ... the door lock and hinge pocket if desired It is important to keep the doors together try clamping the doors together 1 Turn off the Auto Feed select the either right hand or left hand from the control bar on the middle front of the machine 2 Manually put door stop up 3 Set the control buttons to the desired width See the figure above 4 To make minor adjustments to the width on the machine measure...

Page 53: ...nders on back section Feed Belt Feeds Door through Machine Lock Bore Motor and Drill Drills locks holes on the face of the door Ball Catch Motor and Drill Opt BC Drills ball catch top edge Out Feed on LH Door Ball Catch Motor and Drill Opt BC Drills ball catch on top edge In Feed on RH Door Chip Out Location Servo Motor Lock Sec tion Self Centering X Axis Centers the Bolt drill in the X axis Ball ...

Page 54: ...al 2 22 Back View of Rear Section Bolt Drill Extend and Retract Cylinder Face Plate Motor and Bit Routs face plate Bolt Drill Motor Machines lock plate on the side of the door Lock Bore Limit Switches Deep Shallow Retracted Lock Bore Oil Reservoir ...

Page 55: ...on trolled ball screw movements for all router and chisels complete with square lock face plates Backsection will have the ability to machine a face plate at both 0 and 3 degree Bolt Drill Motor Machines lock plate on the side of the door Ball Screw Left Lock Plate Chisel Cylinder Squares the edge of the lock plate Right Lock Plate Chisel Cylinder Squares the edge of the lock plate Z Axis Servo Mo...

Page 56: ...n ball catches When selected the proper drill automatically pivots in to drill into the top of the door Note minimum door width for drilling is 18 Ball Catch Motor and Drill Drills ball catch top edge Out Feed on LH Door Adapts to 6 8 and 8 0 doors Ball Catch Motor and Drill Drills ball catch top edge In Feed on RH Door Ball Catch Cylinder Moves motor assembly to 8 0 or 6 8 door position ...

Page 57: ...Drop Opt O Air Blow off Blows off dust from the door as it Feeds Out Out Feed Door is fed to next stage Six Shooter RH LH Door Indicator Opt IL As the door exits a signal desig nates if door is Right Hand or Left Hand Hydraulic Tank for Six Shooter Sets and Lifts Six Shooter out of Hinge pocket FIGURE 2 16 Key Assemblies on the Out Feed Section ...

Page 58: ...Option IL Left Hand Right Hand Door Indicator Light is be mounted on the out feed end of the 990 F4 that can be seen by the 700 C Assembly Table Operator The light will be on when the door in the 994 X is being machined as a right hand door and off for a left hand door Incoming Right Hand Door Red Light will be on if a Right Hand door is exit ing the machine It will be off if the door is a Left Ha...

Page 59: ... working on the panel follow the safety protocol as described in Chapter 1 Main Electrical Panel The Main Electrical Panel Supplies voltages to the machine Contains the PLC Programmable Logic Controller Contains servo drives to interact with the servo motors Axis and Lock Location in the front and back sections Main Electrical Panel Power Supplies PLC Input Output Terminals 110 V 24 V Terminals Hi...

Page 60: ... routers width adjust motors and feed motors Contactors Thermal Overload and Control Transformer Lock Bore Motor Bolt Drill Motor 6 Shooter screw Driver In Feed Ball Catch Opt BC Out Feed Ball Catch Opt BC 8 Shooter Screw Driver Opt K 110 V 24 V Terminals High Voltage Section Input Output Terminals VFD Section Hinges 1 4 Face Plate Router Feed Motor Width Adjust Pre Drill 1 4 Counter Rotate Router...

Page 61: ...ight 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 activated 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 ...

Page 62: ...n assembly is in between the two sensors the machine will not operate One Package The Proximity Sensor detects metallic objects without touching them 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...

Page 63: ...iddle front of the machine turn the Door switch to RH Right Hand or LH Left Hand Door Turn the Feed Mode switch to ON Auto Feed Preset Buttons Left Hand or Right Hand Auto Feed ON Start Sequence Feed in a door from the Door Feeder In Auto mode the Door will Auto Clamp Insert a Jamb aligning it firmly on all the jamb ledges Press the Jamb firmly against the jamb stop Holding the jamb in place with ...

Page 64: ...tion it into the H Block using the Ryertex guides 1 Press the Start Sequence button to move the Six Shooter into position and drop the screws The six shooter will snap into place 2 When fully seated press the Insert Screw Button to attach the six screws 3 Press the Reset switch to raise the Six Shooter out of the hinge pocket and feed a set of six screws for the attachment of the next hinge 4 Repe...

Page 65: ...ed 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 TRANSFORMER switch to the ON position It should light up 5 Push the green START MACHINE button to boot up the machine Note Boot up may take 2 to 3 minutes Control Transformer Star...

Page 66: ...position at the in feed end of the machine 2 The machine will then move to about the middle of its travel The 994 X is now ready for work How to Power Down the 994 X 1 1 2 3 Select Shut Down System from the Main Screen to close operator interface program and shut down the operating system Note Make sure Windows is shutdown completely before turning off the machine Hard drive or data may be damaged...

Page 67: ... the machine Note Depending on options of the machine the E Stop but tons may be located at various locations 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 is killed The machine responds in the same way if you press the STOP button on the operator s station ...

Page 68: ... information generated is as follows 1 General Machine Status 2 Front Section Status 3 Back Section Status 4 Current Servo Positions Note Use this information to isolate issues if having prob lems with the machine 1 2 3 4 Controlling Access to User Screens The 994 X has the ability to lock out changes to certain parameters such a presets and calibra tions Note Locked out parameters may vary due to...

Page 69: ...ons Door Spec Hinge Spec Back Section Door Controls Feed Controls Clamp Controls Width Controls Machine Controls Stop Door Seq Reset Machine Shut Down System Home Machine Manual Screen Width Adjust Door Stop Clamp Skip Hinges Feed Control Burn Chipout Test Mode Exit Application Jog Lock Location Hinge Servo Jog Manual Jog Jog Hinge Carriage 1 Jog Hinge Carriage 2 Jog Hinge Carriage 3 Jog Hinge Car...

Page 70: ... Pre Drill Template Lock Location 6 8 RH LH 7 0 RH LH 8 0 RH LH Feed Sys timing Jamb Shelf Height Plate Fast Timers Plate Slow Timers Diagnostics 990 H Log screen Total Door Count Daily Door Count See About the Diagnostic Screen on page 2 52 See About the Machine Calibration Screen on page 2 43 Chisels Upper Left Chisel Upper Right Chisel Lower Left Chisel Lower Right Chisel ...

Page 71: ...994 X From this screen all the basic user inter face controls are available to run a door FIGURE 2 19 Main Screen AR HQ2 Option 994 X with an AR HQ option see the AR HQ2 Operation and Service Manual This Manual is included with the Document Package Note For information on Control the direction of the Door after pro cessing by the 994 X ...

Page 72: ...Press Home Machine after Reset Machine Stop Door Sequence Button This button stops the door in the process Shut Down System Button This button shuts down the computer Use this button as part of the shutdown pro cess See How to Power Down the 994 X on page 2 34 Preset Selection Button Group Pressing a preset button calls one of twelve presets stored in mem ory Pressing the Modify Preset button allo...

Page 73: ...ge calibrations Can enable The Split Jamb Stapler Option You can select Pre Drill buttons to down load pre drill parameters or turn off this func tion To set Pre Drill parameters see About the Pre Drill Screen on page 2 47 This section also contains the file list window which displays files that are available to use Back Section Group Set the lock parame ters in the Back Section group The settings...

Page 74: ...o toggle the feed through on or off In feed through mode the door will pass through the machine without processing Auto Width Press Auto Width to toggle the auto width on or off In auto width mode the machine will automatically set the width adjust system for optimum clamping Auto Unclamping Press Auto Unclamping to toggle auto Unclamping on or off The auto unclamp button sets the machine to autom...

Page 75: ...p Button on the Main Screen to open access to the Main Cal Machine Calibration screen Setup Hinge 1 4 screens Pre Drill Setup screen About the Machine Calibration Screen The Main Cal button leads to the Machine Calibration screen In this screen you can perform machine calibration of the lock location and lock bore location on the back section change machine timing and speeds and position the jamb ...

Page 76: ... Moves the lock location for left hand doors only RH Moves the lock location for right hand doors only Feed System Timing Adjustments Infeed Stop This is distance the clamped door is located after the after infeed eye Out feed Stop This is the distance the clamped door is located after the before out feed eye Fast Lock Plate Timing Vertical The amount of time in seconds to give the vertical moveme...

Page 77: ...t of the lock plate when in Slow Plate mode About the Setup Screens 2 45 KVAL 994 X Operation Service Manual About the Setup Hinges 1 4 Screens From these screens you can adjust the parameters of each head Refer to Figure 2 1 on page 3 for head locations Setup Hinge 1 Setup Hinge 2 Setup Hinge 3 Setup Hinge 4 Counter Rotate Route r Option CR only Chisels Option CH only FIGURE 2 21 Hinge Setup Menu...

Page 78: ... and Z direction Router Adjustments These adjustments move routers in the X Y and Z direction The radius of the router cut also may be adjusted Use this to compensate for minor changes in tooling during calibration Option CR Chisel Adjustments These adjustments move Chisels in the X Y and Z direction Use this to compensate for minor changes in tooling during calibration About the Setup Screens KVA...

Page 79: ...22 Pre Drill Screen The X and Y valves are referenced off the bottom of the hinge on the door to the center of the hinge The jamb pre drill holes are equal to the mirror image of the parameters entered This allows for less time entering data and keeps precision drilling patterns The number 0 entered in both X and Y are equal to no drill Important Never enter a negative number in the Y parameter Th...

Page 80: ...Zero Point Y Zero Point Sample of 4 Hinge Dimensions X Zero Point Y Zero Point Sample of 3 5 Hinge Dimensions About the Setup Screens KVAL 994 X Operation Service Manual 2 48 FIGURE 2 23 Pre Drill Samples ...

Page 81: ...l About the Manual Operation Screens 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 FIGURE 2 24 Manual Operation Screen FIGURE 2 25 Jog Carriage screen ...

Page 82: ... the feed release the button Forward Press and hold the Forward button to move the door feed forward To stop the feed release the button Normal Speed Press and hold the Normal Speed button to slow speed To return to previous speed release the button Toggle Buttons The buttons to the right toggle auto functions on or off For descriptions of these but tons see Auto Enable and Disable Buttons on page...

Page 83: ...operator needs to use a different Windows application Jog Hinge Location Carriage 1 4 X Axis Left or Right Press and hold buttons to jog the hinge carriage location left or right To stop release the button Y Axis Up or Down Press and hold buttons to jog the hinge carriage location up or down To stop release the button Z Axis Out or in Press and hold buttons to jog the hinge carriage location in or...

Page 84: ...ne 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 The Diagnostic screen keeps track of the all the doors processed on the machine The quantity is displayed in the Total Door Count box To keep track of daily production the quantity of doors produced in a day is ...

Page 85: ...ces to the Operator Screens This section details the added features to the operator screens Note To read about all menu choices see Description of User Interface Screens on page 2 36 Option SB Main Menu Screen The following is added to the Main Screen in the CNC Back Section option Square Plate Tog gle to turn the square plate cutting routine ON or OFF Lock Plate Adjust Lock Plate ti the X Y and Z...

Page 86: ...ck Section option Lock Location See Lock Location Adjustments on page 2 44 Fast Lock Plate Timing See Fast Lock Plate Timing on page 2 44 Slow Lock Plate Location See Slow Lock Plate Timing on page 2 45 Lock Carriage Calibrates the Back Section Carriage in the X Y and Z direction Zero and Three degree X and Y are calibrated separately Router These adjustments move router of the back sec tion in th...

Page 87: ...utton make i easy to change tools on the lock section head The buttons are located in the Manual screen Use the two buttons in tandem Lock Access Button with Access Tools OFF The Lock Plate will move to a position for easy access Lock Access Button with Access Tools ON Moves the Lock Plate out further if more room is needed to access tooling ...

Page 88: ...Option SB About the CNC Back Section Operator Screens KVAL 994 X Operation Service Manual 2 56 ...

Page 89: ... when to calibrate Page 3 2 About the Calibration Routine Specifications of the Calibration Routine Page 3 4 Run the Calibration Routine Details on running a calibration reference for the Front Page 3 6 Check and Adjust Front Section Calibrations Details on using the calibration screens to adjust he Front section tools Page 3 7 Check and Adjust Back Section Calibrations Details calibration the Bac...

Page 90: ...he cutting tools Using this function will allow the operator observe any major issues during the machine cycle without damaging tooling or product See About the Manual Operation Screens on page 2 49 Before you start calibration check for the following common issues and ask yourself these ques tions 1 Is the loaded setup correct for the current cut 2 Are the machine stops set up correctly 3 When di...

Page 91: ...ut Calibration 3 3 KVAL 994 X Operation Service Manual Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the 994 X FIGURE 3 1 Calibration Process Flowchart ...

Page 92: ... slot for inaccuracies The front end assemblies that use the calibration routine are as follows 1 Hinge Carriage 2 Router Standard 3 Option CR Counter Rotate Router to eliminate chipouts 4 Option CH Chisels to square the cut 5 Pre Drill Pre Drill Drills pilot holes for insertion of screws on the jamb and the door Router Routs the hinge pocket on the jamb and the door Counter Rotate Router Router m...

Page 93: ...oor width For information on making adjustments see Check Specifications of the Front Sec tion on page 3 7 TABLE 3 2 Cal Slot Dimensions Assembly Length Width Depth Vertical Position Position Standard Router 2 00 Diameter of Drill Diameter of Router 0 050 Center of Door Edge Center of H Block C Rotate Router 2 00 Diameter of Drill Diameter of Router 0 100 Center of Door Edge Center of H Block Dril...

Page 94: ... con tact KVAL service KVAL service can remotely download the program if LAN and WEB enabled FIGURE 3 3 Calibration Routine Selection Select Door Parameters From the Door section of the User Interface choose the following below 1 Choose Door Height Thickness 2 Choose Door Length 3 Disables Hinge 2 of the hinges leaving one hinge enabled Load the Door and Start the Cut 1 Load the test door into the...

Page 95: ...number by using your Left Hand Use the cut on the door as a reference Hold out the left hand with the first finger pointed at the door second fin ger and thumb at right angle to each other The first finger represents the positive direction of the Z axis the thumb represents the positive direction of the Y axis then second finger represents the positive the direction of the X axis Y X Axis Positive...

Page 96: ... box below the parameter The Base display box keeps a running total of data entered to help keep track of the changes The Combine with Base button stores data in memory and should be used at first to set a reference and at final to store data See Check Specifications of the Front Section on page 3 7 for information on direction of servo motors Title of assembly to adjust Parameter to adjust X Y an...

Page 97: ...e amount of material left between the H block and the slot on both sides of the slot a and b 3 Calculate the difference between a and b and then divide by two See Figure 3 6 on page 3 10 4 Next what way does the slot need to move To move to the left enter a positive number To move to the right enter a negative number 5 Locate the appropriate Menu in the Setup interface screens 6 If there is a numb...

Page 98: ...r Width and the slot on both sides of the slot a and b 3 Calculate the difference between a and b and then divide by two Refer to the example located below 4 Next what way does the slot need to move To move up enter a positive number To move down enter a negative number 5 Locate the appropriate Menu in the Setup interface screens 6 If there is a number in the box under Y Axis select the Combine wi...

Page 99: ...own a b a b FIGURE 3 7 Adjustments for the Y Axis Adjusting the Z Axis 1 Run the Calibration Routine See Run the Calibration Routine on page 3 6 2 Measure the depths of the Router and Pre Drill 3 If depths are off go to the Setup screen and select the appropriate Z menu 4 If the depth is too deep enter a negative number of the difference of the measured and the desired depth 5 If the depth is too ...

Page 100: ... Combine with Base 4 X To move the cut to the right enter a positive value To move the cut to the left enter a negative number Y To move the cut to up enter a positive value To move the cut to the down enter a negative number Z To increase the depth enter a positive value To decrease the depth enter a neg ative value Diameter The diameter menu allows adjustment compensate for discrepancies to the ...

Page 101: ...egative number Z To increase the depth enter a positive value To decrease the depth enter a negative value Diameter The diameter menu allows adjustment compensate for discrepancies to the actual size of the router bit If the diameter is not correct it will affect the X Y and Z parameters Step 3 Pre Drill Calibration Verify the Pre Drill The depth of the pre drill should be 0 250 deep The hole shou...

Page 102: ... value To move the cut to the down enter a negative number Z To increase the depth enter a positive value To decrease the depth enter a negative value Check Specifications of the Front Section KVAL 994 X Operation Service Manual 3 14 FIGURE 3 9 Pre Drill Router Calibration Menu 5 Repeat until hole is centered 6 Select Combine with Base to finish ...

Page 103: ...eck that the H block is setup in the correct location 3 Run the hinge 4 After the hinge run is finished check all four corners of the hinge to see if the chis els are in the correct location 5 If the corners of the hinge are out of specification continue the process on the next page Select button to gain access to the Chisel Calibration menu Upper Left Chisel Lower Left Chisel Lower Right Chisel U...

Page 104: ...per to measure how much the chisel cut is off compared to the hor izontal hinge cut with the router on the jamb a Take the caliper measurement and enter it into the Y axis box b If the chisel needs to move down enter it as a negative number c If the chisel needs to move up enter a positive number d Repeat until chisel position is correct Positive Negative 5 Z Axis use a caliper to measure the dept...

Page 105: ...n to access Lock Location Calibration Lock Bore Location r t FIGURE 3 10 Path to Calibration screen Back Section Lock Location Calibration To start run a known good lock cut at a standard location on a Right Hand or Left Hand door Once the lock cut is completed check the distance from the top of the door to the center of the lock Note the measurement value and compare to specification If the lock ...

Page 106: ...eps 3 to 4 until the center of the lock is at the desired cut location 7 Once the completed with calibration select the Combine with Base button to store the data 8 Exit Main Calibration Screen Fast and Slow Lock Plate Timing Adjust Fast Lock Plate Timing under normal operating No Extend Time the router time can be adjusted to match the flow controls on the machine Before adjusting these times mak...

Page 107: ... a larger number This number is in seconds If there is a delay before the vertical moves enter a smaller number in this box Continue entering numbers until timing is matched Option SB CNC Back Section Calibration This section describes calibration screens for the optional CNC back section Lock Carriage Calibrates the Back Section Carriage in the X Y and Z direction Zero and Three degree X and Y ar...

Page 108: ...so may be adjusted Run a known good lock bore at a standard location on a Right Hand or Left Hand door Once the lock bore is completed check the distance from the top of the door to the center of the bore hole Note the measurement value Positive Negative Chisel Calibration Back Section These adjustments move Chisels in the X Y and Z direction Use this to compensate for minor changes in tooling dur...

Page 109: ...red direction X Y Z Positive number moves tools in nega tive number moves tools out Positive Number Negative Number Positive Number Negative Number Upper Right Upper Left Lower Left Lower Right Calibration of the Back Section 3 21 KVAL 994 X Operation Service Manual ...

Page 110: ...Calibration of the Back Section KVAL 994 X Operation Service Manual 3 22 ...

Page 111: ...s the operation of the machine With the controller KVAL can remotely help troubleshoot your machine Chapter 4 at a Glance Section Name Summary Page System IT Administration This chapter describes the basic parts of the operation of the PLC in the machine Such as About the PLC Connections on the PLC Backing up the Computer About Remote Connection to KVAL Service Page 4 2 ...

Page 112: ...ry The computer has a removable Compact Flash card from which it boots The controller uses a Windows 7 oper ating system with TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include A smart power supply to connect to EtherCat terminals This supply contains a LCD to display system and user messages A DVI USB module to connect to the user interface An Ethe...

Page 113: ... 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 994 X machine With the remote access our KVAL service technician is able to observe your user screen in real time read and...

Page 114: ...System IT Administration KVAL 994 X Operation Service Manual 4 4 ...

Page 115: ...scribes the suggested maintenance steps to perform 300 Cycles 600 Cycles 3 000 Cycles 12 000 Cycles 72 000 Cycles Page 5 2 Tool Changing Schedule Describes the suggested time frame to change the tools in the machine Page 5 14 Lubrication Requirements This section describes the lubrication requirements for the machine including types of lube to use This section includes Linear Bearings Flange Beari...

Page 116: ...ior 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 Clean Use pressu...

Page 117: ...ean 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 cylinder rods with dry silicone spray Lubricate Lubricate all bearing shaf...

Page 118: ...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 Front Section Underneath Car riage Heads Jamb Clamp area High Dust Accumulation Areas Lock Bore Area build up can occur and stop Bolt drill ...

Page 119: ...roper 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 Drill Bits Cutting Tools Screw Driver Bits See Replacing Tooling in the Front Section on page 5 21 and see Replacing Tooling in the Back S...

Page 120: ...icate the input to the screw drop hoses Provides an easier screw drop Do not over spray oil Empty Dust Collection Units Check and empty any dust collection units Clean any dust filters Dust collection systems vary from machine to machine Follow manufacturers directions to empty dust collection units Filters Dust Collection Containers FIGURE 5 14 Typical Dust Collection Unit ...

Page 121: ...eck 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 Six 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 Connec...

Page 122: ...cking 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 R...

Page 123: ...ns 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 instal...

Page 124: ...ings Grease ball screw bearings if applicable For a table of lubrication types to use Lubrication Schedule For locations to lubricate See Ball Screws If Applicable Clean Bearing Shafts Clean all bearing shafts with clean dry cloth Spray shaft with silicone oil and clean build up grime and dirt ...

Page 125: ...tch 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 Hydraulic Lines Inspect hydraulic lines for loose fittings leaks and cracks Insp...

Page 126: ...s for pitting or abrasions Example of a Pitted Ball Rail 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 127: ...h transition with a door feeding into and out of machine Feed door in and out to verify smooth tran sition is repeatable Electrical Check all connections in each node box and electrical panel Wires may become loose due to vibration Check contactors for wear Computer Backup Backup computer software Wash Filter and Lubricator Bowls Wash filter and lubricator bowls with soapy water Slide lock down to...

Page 128: ...ing 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 Hinge Router and Pre Drill Tooling Hinge Router Bit 1500 cycles Chisels Inserts 1500 cycles Chip Out Block 10 000 20 000 cycles 9 64 Pre Drill Bit 10 000 20 000 cycles 1 8 Pre Drill Bit 10 000 20 000 cycles Lock Se...

Page 129: ...Tooling Screwdriver Bits 1 500 cycles Steel Rings 7 500 cycles Rubber Rings 7 500 cycles Screw Receivers 30 000 cycles Split Shells 30 000 cycles Springs 30 000 cycles Tool Changing Schedule 5 15 KVAL 994 X Operation Service Manual ...

Page 130: ...hese conditions are changed timing accuracy or damage may occur during the machine process Do not adjust air PSI above or below factory settings Do not adjust any and all flow controls from factory settings Do not remove shim stock Do not Change or Alter any safety assemblies E Stops Gate Locks etc Do not Change programs in PLC s or PC s Do not Alter Electrical Components ...

Page 131: ... Lith Grease KVAL P N Lube EP 2 Pillow Block Bearing Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation 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 S...

Page 132: ...systems on the machine Linear Bearings Flange Bearing and Pillow Blocks If the bearing is equipped with a grease fitting Zerk Fitting it should receive 1 Gram one pump from grease gun of Dura Lith Grease KVAL 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 Loca...

Page 133: ...ion points Ball Nut Ball Screw End Bearing End Bearing FIGURE 5 16 Example of a Typical Ball Screw Important Make sure to clean excess grease to avoid contact with feed belts clamping areas or the door 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 lubricat...

Page 134: ...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 every other cycle is a good rule of thumb The approved list of oil for lubricators is as fol lows KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32 Gulf Harmony 32 To prime the lubricator find an air line ...

Page 135: ...ction describes the steps to change the pre drill bits router bits and chisels in the heads on the front section shows the locations of the replaceable parts inside the heads Pre Drill Drills pilot holes for insertion of screws on the jamb and the door Router Routs the hinge pocket on the jamb and the door Counter Rotate Router Router minimizes chip outs on door and Jamb Pre Drill Router Standard ...

Page 136: ...r to access the bit assemblies Remove and Replace the Router or Pre Drill Bits Caution Before performing this process turn off all power to the machine Follow proper lockout tagout procedures as detailed in the safety section of Chapter 1 of this manual 1 Use a 17 mm shaft wrench and a 3 8 collet wrench to remove the bit on the pre drill or router assemblies See Figure below 3 8 Collet Wrench PN P...

Page 137: ...embly 5 Before tightening the collet assembly adjust the bit depth Set the router bit to 1 3 4 and the drill bit to 2 0 from the base of the collet nut to the tip of the bit If available use Bit Depth Gauge PN 432 C to set the depth 6 Lightly tighten and torque to correct value For torque values Collet Torque Values Drill Depth Set to 2 0 Router Depth Set to 1 3 4 1 3 4 2 0 Bit Depth Gauge PN432C ...

Page 138: ...Note the orientation of the chisel FIGURE 5 22 Replacing the Chisels 5 Slide in the new chisels 6 Tighten bolts back and forth until the bracket is tight 7 Inspect and verify the work Clean the work area 8 If maintenance is completed replace dust cover and tighten bolts Remove and Replace the Screwdriver Bits To replace screwdriver bits on the Six Shooter heads follow the instructions below 1 Turn...

Page 139: ...ewdriver bit push the bit holder see images back toward the Six Shooter assembly and hold pull bit out of holder Slide Back Bit Holder 7 To insert screwdriver bit push bit holder back toward Six Shooter assembly and hold while inserting new bit Release holder to secure bit 8 Move Six Shooter assembly back toward machine and pull the back slide toward you then move assembly away from machine to res...

Page 140: ...te will move to a position for easy access Lock Access Button with Access Tools ON Moves the Lock Plate out further if more room is needed to access tooling Changing the Bore Drill 1 Remove Dust Collection Guard 2 Use the shaft wrench and collet wrench to remove the bit on the pre drill or router assemblies See photo When loosening the collet it may tighten up crack again and con tinue 3 Inspect a...

Page 141: ... When loosening the collet it may tighten up crack again and continue 2 Inspect and clean collet assembly 3 Insert the new bit into the assembly 4 Before tightening the collet assembly adjust the bit depth Bottom out the bit and pull the bit up about 1 4 5 Lightly tighten and torque to correct value For torque values Collet Torque Values Note Make sure the arbor is not bottomed out in the back of ...

Page 142: ...ERVS503 3 HP 3 00 SOYUS 20 Hook 36 ft lbs GC90E1683 7 5D 7 5 ER 32 Slotted 100 ft lbs PERKRSV51 14 2D 7 00 SOYUS 25 Hook 90 ft lbs COLS116150 10 D 10 0 ER 40 Slotted 130 ft lbs HSD Motor KVAL Part Number Horse Power Type Collet Type Nut Torque Value COLS63F0020 11D 11 0 ER 40 Slotted 130 ft lbs A6161H0824 HSD Spin dle Motor 10 0 ER 32 Slotted 100 ft lbs COLS135501 12D 12 0 ER 40 Slotted 130 ft lbs...

Page 143: ...f the bit to the bottom of the tool holder Periodically use compressed air to clean both the nut and collet Check the collet for bluing Overheating or damage If it is damaged or over heated re place it When inserting the collet into the nut it should SNAP in to place Snap Nut 1 8 Min Collet Bit Collet Torque Values 5 29 KVAL 994 X Operation Service Manual ...

Page 144: ...Collet Torque Values KVAL 994 X Operation Service Manual 5 30 ...

Page 145: ... point for troubleshooting Page 6 7 Using Sensors to Troubleshoot Includes the voltage values of sensors during machine operation Page 6 22 Troubleshooting Electrical Problems Includes voltages in the electrical panels using the Sta tus Light panel to troubleshoot and VFD troubleshoot ing Page 6 25 Network System Overview Network overview View of Network layout Servo call outs Location of VFD s Pa...

Page 146: ...g a load from one fixed position to another fixed position at a constant speed and along one line axis X Y or Z A typical point to point would be a drill with a fixed depth The drill is either retracted or extended using a pneumatic cylinder Typically the drills travel is limited by physical stops Incremental Incremental motion control is used when the load is required to be moved with high accura...

Page 147: ...oller Translates entered information into a form the positioning system can understand Listens to the machine s other subsystems waiting for the OK to move command Sends the positioning instructions to the positioning system Listens to the positioning system for position status if there is a feedback loop Tells the machine s other subsystems when the move process is completed Examples A PLC or a d...

Page 148: ...ting heavy motor currents The figure below shows a block dia gram of a typical contactor circuit with typical voltages PLC Output Fuse s Line Voltage Power Motor 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 Should measure Line Voltage here ON Relay 120 VA...

Page 149: ...s a block diagram of a typical motor drive circuit with typical voltages Common Motor Drive Control PLC Output Fuse s Line Voltage Motor Power Motor Power Input Output Power Control Circuit Common ON Should measure Control Voltage 24 VDC here Should measure Line Voltage here Should measure Line Voltage here ON Drive STF Forward RL STR Revers 2 SD COMMON OFF OFF OFF Run 300 Run Light should be ON S...

Page 150: ...chine For Example extending and retracting router drill clamping a door PLC Output High Pressure Air Cylinder Common Control Circuit ON Should measure 24 VDC here Control Voltage Should have High Pressure air here Extended Cylinder Retracted Control Control Coil Input Air Input Air Output Valve Should have High Pressure air on Activated Output FIGURE6 26 Block Diagram of a Pneumatic Circuit ...

Page 151: ...6 1 on page 8 for sequence and subsystem information Verify Verify or analyze the subsystem assembly that is responsible for the issue For example How is the subsystem supposed to work What is keeping the subsystem from working Note See Analyze the Sub Systems on page 6 8 for information on verifying and analyzing subsys tems Before you Adjust Sometimes simple problems can seem to be complex issue...

Page 152: ...eed System 6 Wait for Next Door Feed System Basic Troubleshooting Steps Determine Where The Sequence Step Where the Failure Occurs What was the Machine Trying to Do What Was the Machine Trying to Do Next How is the Broken Section Suppose to What is Keeping the Broken Section From Working What Part of the Machine is not Work ing Ask Narrow Verify Troubleshooting Basics KVAL 994 X Operation Service ...

Page 153: ...roper sensors are activated If the controller is a PLC an activated input is lit Some touch screens have inputs status also 3 Common Position Feedback failures Photo Eye Bad element or bad cable Limit Switch Stuck or failure Wiring Broken worn insulation PLC Bad input port 4 Check the Positioning System Follow the circuit from the Controller output to the Load and check for component failures ...

Page 154: ...tage 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 Shou...

Page 155: ...nel as a trigger to check the circuit See Troubleshooting with the Status Light Panel on page 6 26 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 ver...

Page 156: ...leshooting 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 Fre...

Page 157: ...ck diagram see Figure 6 29 on page 6 12 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 wi...

Page 158: ...l be 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 t...

Page 159: ...ssure 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 ...

Page 160: ...nput 24V from PLC to open a port FIGURE 6 33 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 o...

Page 161: ...r is delivered to port B FIGURE 6 35 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 rig...

Page 162: ...er 24 V Applied Router Assembly Load Position Feed Back Air In Control Valve Extend Sensor Activated Air Pressure Extends Cylinder and Router Assembly 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 ...

Page 163: ...t 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 mech...

Page 164: ...eration Service Manual 6 20 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 165: ...is 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 The distance from an eye to the door should be in range Typically the range should be 3 4 to 7 8 from the top of all eyes to the door ...

Page 166: ...nation represents an output from the PLC Inside of Fence Outside Of Fence Narrow Door Outside Option Narrow Door Inside Option Door Sense Eye Before In Feed Stop Door In Machine After Out Feed Stop Eye After In Feed Stop Width Adjust ment Sensors Valve Bank 1 Q Designators Width Adjust ment Sensors Valve Bank 2 Q Designators Valve Bank 3 Q Designators Before Out FeedStopEye FIGURE6 36 Location of ...

Page 167: ...s sets the maximum limits in positive and negative vertical movement and also sets the home position The Z Axis sensors sets the maximum limits in positive and negative depth move ment and also sets the home position Y Axis Home Eye Y Axis Forward Crash Eye Y Axis Reverse Crash Eye Z Axis Home Eye Z Axis Forward Crash Eye Z Axis Reverse Crash Eye FIGURE6 37 Figure 6 37 Section View of 994 X Y and ...

Page 168: ...ows the placement of the X Axis sensors The X Axis sensors sets the max imum limits in positive and negative positions and also sets the home position The sensors are located underneath the Heads X Axis Home Eye X Axis Forward Crash Eye X Axis Reverse Crash Eye FIGURE6 38 Bottom View of 994 X location of X Axis Sensors ...

Page 169: ...chines 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 a...

Page 170: ... 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 sect...

Page 171: ...elow 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 6 28 STEP 2 Overload Relay Amber If light is OFF go to item B on Page 6 29 STEP 3 E Stop Amber If light is OFF go to item C on Page 6 29 STEP 4 Stop Amber If light is OFF go to item D on Page 6 29 STEP 5 Start Amber If light is OFF g...

Page 172: ... 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 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 but...

Page 173: ... see the 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 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...

Page 174: ... VAC If no 110 VAC check the fuse If there is 110 VAC and no 24VDC replace the 24VDC Power Supply 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 ...

Page 175: ...stance to vibration and impact Figure 6 39 below shows the PLC connections in the 990 H The PLC is located in the Main Electrical Panel From the PLC connections are made to coupler interfaces located near the sec tions they control See your machine s schematic package for detailed wiring information To aid in troubleshooting the next section shows the locations of the assemblies in the block dia g...

Page 176: ... For detailed wiring information see your machine s electrical drawings 24 VDC Input Ether CAT Output Ether CAT Input From PLC High Voltage Input Servo Drive 1 2 High Voltage Servo Drive 2 2 High Voltage Outputs Servo Drive 3 2 High Voltage Servo Drive 4 2 High Voltage Servo Drive 5 2 High Voltage Outputs Servo Drive 6 2 High Voltage Outputs Servo Drive 7 1 High Voltage Output FIGURE6 40 Servo Dri...

Page 177: ... Operation Service Manual Connections to VFD s High Freq Panel The VFD servos are located in the High Freq Electrical Panel For detailed wiring information see your machine s electrical drawings VFD s are located in the High Frequency Panel ...

Page 178: ...ension Hinge Pocket Brake Out 1 Flow Control Out of Adjustment 2 Worn Out Chipout Blocks 3 Worn Out Tooling 1 Readjust as Needed 2 Replace the Chipout 3 Sharpen or Replace the tool Router Has Excessive Noise or Vibrations 1 Bent Arbor Shaft 2 Tool Out of Balance 3 Router Loose in Housing 1 Replace Arbor 2 Replace Tool 3 Tighten Router in Housing Feed System Doesn t Stop for Door to Clamp 1 Debris ...

Page 179: ...1 Horizontal Router Ferrous Prox imity Sensor not Sensing 1 Look For Obstructions 2 Adjust Ferrous Proximity to within 1 31 or the reading sur face Router Fails to Operate 1 Bad Fuse 2 Routers Unplugged 1 Replace Fuses 2 Plug In Routers Stuck in Pocket Position Pre Drill Only 1 Emergency Stop has Occurred 2 PowerFailure ThruBeamsOutof Alignment 1 Re energize Computer 2 Hit Router Out of Pocket Pos...

Page 180: ...Symptoms and Possible Causes KVAL 994 X Operation Service Manual 6 36 ...

Page 181: ... assemblies3 4 lock location3 17 path to hinge setup3 8 pre drill3 13 3 15 3 20 slot dimensions3 5 steps before3 2 suggested order of steps3 9 chisels remove and replace5 24 collet assembly inspection5 23 5 26 5 27 combine with base how to use3 8 computer as a PLC4 2 backing up4 2 4 3 control panel light not on troubleshoot6 28 control power indicator light description2 29 control transformer swit...

Page 182: ...hine2 31 K KVAL getting help1 15 L LCD display smart power supply4 2 Left Hand Rule3 7 linear bearing maintenance schedule5 17 lock calibration3 17 lock access to user screens2 36 lock location adjusting location3 18 lockout and tagout Guidelines1 13 lockout procedure1 11 M machine calibration group description2 44 machine feed back user output2 36 machine feedback front section status2 36 general...

Page 183: ...its remove and replace5 24 sensors location on frame6 22 troubleshooing6 21 types2 30 voltage levels2 30 x axis and y axis locations6 23 service connecting your machine to KVAL Service4 3 service center contacting information1 15 servo drives connections location6 32 location in main electrical panel2 28 servo positions feedback2 36 setup hinges group location2 45 setup screens2 43 shut down syste...

Page 184: ...face description2 50 Windows CE operating system about4 2 X X axis calibration routine3 9 illustration of adjustment3 10 Y Y axis calibration hinges3 10 illustration of calibration3 11 Z zerk fittings5 18 locations5 18 zero energy start up clean up1 13 inspect1 13 ...

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Page 188: ...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 ...