Kval Commander III, Service Manual

Page 1: ...Innovation Quality Honesty Service Manual Published 10 9 19 Commander III Door System With KvalCam Commander III Service Manual ...

Page 2: ...s 7 is a registered trademark of Microsoft Corporation All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated Contacting KVAL Customer Service For further information about this manual or other Kval Incorpo rated products contact the Customer...

Page 3: ...er 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 ...

Page 4: ...nerated through the KVALCAM Software are also the property of the Licensor and are protected by applicable law 1 Definitions a KVALCAM Software means the KVALCAM computer application installed in the KVAL Machinery and written documentation and materials provided to you as well as any revisions or updates of such computer application and documentation b Install means storing of the KVALCAM Softwar...

Page 5: ...KVAL Commander III Service Manual KVAL Commander III Service Manual ...

Page 6: ...umb 1 12 Zero Energy to Start Up 1 13 Zero Energy State to Start Up to Operating State 1 13 Getting Help from KVAL 1 15 On Line Help 1 16 Product Return Procedure 1 16 How to Download the Service Application 1 18 Download Application 1 18 Safety Sign Off Sheet 1 21 A Note to the Operator 1 21 Chapter 2 System IT Administration System IT Administration 2 2 About the Commander III Computer 2 2 Conne...

Page 7: ... 10 Inspect Ball Rail Shafts and Ball Screws 3 11 Clean and Lubricate Slides Cylinder Rods and Bearing Shafts 3 11 72 000 Cycle Maintenance Steps 3 12 Inspect Nuts and Bolts 3 12 Check Door Feeding Transition 3 12 Electrical 3 12 Computer Backup 3 13 Wash Filter and Lubricator Bowls 3 13 Maintenance NO GOES 3 14 Lubrication Schedule 3 15 Typical Lucubration Kit 3 15 Lubrication Requirements 3 16 P...

Page 8: ...tion Drill Assembly 3 37 Collet Torque Values 3 38 Chapter 4 Troubleshooting the Commander III Get Live Technical Help 4 1 About Motion Control 4 2 Basic Control Circuit 4 3 About a Typical Contactor Control 4 4 About Contactor Troubleshooting 4 5 About Typical VFD Motor Drive Control 4 6 About the VFD 4 7 About VFD Troubleshooting 4 8 About a Typical Pneumatic Circuit 4 9 Typical Pneumatic Assemb...

Page 9: ...t Panel 4 19 Control Power Light OFF 4 20 Overload Relay Light OFF 4 21 E Stop Light OFF 4 21 Stop Light OFF 4 21 Start Light OFF 4 22 24VDC Light OFF 4 22 Network System Overview 4 23 Connections to Servo Drives 4 23 Connections to VFD s High Freq Panel 4 23 ...

Page 10: ...Notes ...

Page 11: ...t IMPORTANT safety information is described in this sec tion 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 specification plate tor provide to KVAL service center hours and return procedures page ...

Page 12: ...econd hinge location A couple of manual adjustments for H blocks and jamb clamps are still necessary but a pointer and setup mode reduce this to under two minutes and eliminates errors Lock Locations fully automatic positioning for lock locations from the door top and up to three locks can processed on one door Program selection for lock hole backsets of 2 3 8 or 2 3 4 and either 1 or 1 1 8 face p...

Page 13: ...chine s industrial PC and CNC positioning motors to completely automate hinge pattern processing and lock locations Door files can be created with the software which can reference barcode labels or be selected from an on screen list for nearly instant machine set up The door files hare identical to those used in the Kval Face Edge and DLNC series machines so one file can be created to be used in m...

Page 14: ... Gearbox with Air motor See Above Option W Option W3 Schlage D Serial 792 Drill Gearbox with Air motor See Above Option W Option W4 Yale 80 7150 0047 010 Drill Gearbox with Air motor See Above Option W Option W5 Corbin Russwin VT30458 Drill Gearbox with Airmotor See Above Option W Option Title Description ...

Page 15: ...f Sheet on page 1 21 Operation Manual includes the following Service Manual includes the following Chapter Title Description 1 Introduction Descriptions of Machine Line and Safety Information 2 About KvalCAM Descriptions of the KvalCam user interface 3 Operation Inter face Descriptions of how to power machine line and operator inter face user screens 4 Calibration Descriptions of Calibration Rou t...

Page 16: ...maged 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 the warning is not heeded it can cause death or serious injury CAUTION means if the precaution is not taken it may cause minor or moderate injury Safety Guidelines In addition to the caution and warning labels affixed to this machine ...

Page 17: ...down Never perform any maintenance unless machine is 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 Befo...

Page 18: ... switch Some machines are powered by more than one supply located at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when cl...

Page 19: ...alth regula tions which apply in your geographic area Compliance with Codes and Regulations Other Hazard Control Action Report a Hazard Before You Report an Accident If you believe any part or operation of this machine 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 safet...

Page 20: ...ht shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shut down 3 Obtain locks keys and tags from your employer s lockout center 4 Disconnect power a Turn the disconnect switches on the main electrical panel to the OFF position Then pull out the red tab and place a padlock through the hole Place your tag on the padlock as per the tagout guidelines below see ...

Page 21: ...ty devices are installed 8 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 9 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 10 The tags must be destroyed and the locks and keys returned to the lockout center Lo...

Page 22: ...evice 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 lock and tag E ENERGY Release stored energy to a zero energy state R Recheck controls and test to ensure they are in the OFF state ...

Page 23: ...n Please be advised that some com ponents of the machine may start automatically when energy is restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is started Perform Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the personnel alarm befo...

Page 24: ...t procedures work because you are the only one with the key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect ...

Page 25: ...ecification Plate and record the serial number 3 phase volts electrical print number and air print number Air Driven Machines 2 Contact our customer support team 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 address is service kvalinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 ...

Page 26: ...wers to the following questions What is the extent of the failure reason for return What are the relevant error mes sages or error codes How long did it operate Did any other items fail at the same time What was happening when the unit failed e g installing the unit cycling power starting other equipment etc How was the product configured in detail Which if any cables were modified and how With wh...

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 Google...

Page 28: ...l Program is ready to allow technicians to access machine computer Your Name Field Enter your name The KVAL techni cian will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connection 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 Suppo...

Page 29: ...How to Download the Service Application 1 19 KVAL Commander III Service Manual Page Intentionally Left Blank ...

Page 30: ...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 31: ...Safety Sign Off Sheet 1 21 KVAL Commander III Service Manual ...

Page 32: ...operation of the machine With the controller KVAL can remotely help troubleshoot your machine Chapter 2 at a Glance Section Name Summary Page System IT Administration This chapter describes the basic parts of the opera tion of the PLC in the machine Such as About the Commander III Computer Connections on the PLC Backing up the Computer About Remote Connection to KVAL Service page 2 2 ...

Page 33: ...ternal main memory The com puter has a removable Compact Flash card from which it boots The controller uses a Windows 7 operating 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 i...

Page 34: ...Backup Logs Click to save the to save all data from the machine operation notes may be added to describe the saved file Backup and Export Click to send machine data to a text file The file may be sent to Service Support if any issues occur Notes may be added to describe the saved file Note Kval recommends backing up locally and to a isolated server Build Info Click to view upper level notes about ...

Page 35: ...ess is a powerful tool to help fix issues that occur with this machine With the remote access our KVAL service technician is able to observe your user screen in real time read and adjust programming code See Getting Help from KVAL on page 1 15 for more information Network Diagram The desired network topology is illustrated below ...

Page 36: ...Notes ...

Page 37: ...this chapter Section Name Summary Page Maintenance Schedule This section describes the assemblies to schedule for maintenance Daily Weekly 5 Six Month Checkups page 3 2 Lubrication Requirements This section describes the lubrication requirements for the machine including types of lube to use This section includes Linear Bearings Flange Bearing and Pillow Blocks Gear Motor Lubrication Requirements ...

Page 38: ...ng 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 300 Cycles Clean Use pressured air to blow off dust and debris on entire machine Clean Blow out dust collection cans 600 Cycles Inspect Air Pressure Gages Adjust if ...

Page 39: ...w bearings if applicable 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 Inspect Inspect ball screw for pitting or abrasions Lubr...

Page 40: ...ust 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 High Dust Accumulation Areas ...

Page 41: ... 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 the Tooling for wear Drill Bits Cutting Tools See Remove and Replace the Router or Pre Drill Bits on page 3 33 ...

Page 42: ...st 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 3 2 Typical Dust Collection Unit ...

Page 43: ...traction on door Check belts for slickness or door slippage Inspect all Photo Eyes Inspect Limit Switches Inspect all photo eyes secure and tight Check Connection to Photo Eye Check Nut that attaches Photo Eye to Machine Check for debris and clean if needed Inspect all limit switch arms for tightness or breaks Inspect the switch for cracks in the body and check that the switch arm actuates clickin...

Page 44: ...assembly Check Hoses for kinks and rubbing manifold connections and Air Cylinder connections Refill Lubricators If Applicable Not all machines have lubricator option installed Check your machine or Air prints to verify installation 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 t...

Page 45: ... screw bearings if applicable For a table of lubrication types to use see Lubrication Schedule on page 3 15 For locations to lubricate see Grease Ball Screw Bearings on page 3 9 Clean Bearing Shafts Clean all bearing shafts with clean dry cloth Spray shaft with silicone oil and clean build up grime and dirt ...

Page 46: ...ld be 2 to 3 percent of the distance between the centers of the two end sprockets The measurement should be taken at the center of the chain with a tension gauge 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 Not ...

Page 47: ...il Shafts and Ball Screws Inspect ball rail shafts and ball screws for pit ting or abrasions Example of a Pitted Ball Screw 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 ...

Page 48: ...d door in and out to verify smooth tran sition is repeatable Electrical The following checks require the electrical panel to be energized These troubleshooting checks must be performed by a Qualified Electrical Technician Warning This machine is a powerful electro mechanical motion control system If servicing this machine fol low the safety guidelines Failure to do so can result in damage to equip...

Page 49: ...puter software See About Backing up the Data on page 2 3 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 necessary Clean bowls and reas semble ...

Page 50: ...ese 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 51: ...ine Operation Tapered Bearing One Pump 4 X a Year Maximum 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 Gulf Harmony 32 Gear Box 2000 Hours of Machine Op...

Page 52: ...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 53: ...r reliable operation Greasing Flange Bearing 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 4 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 G...

Page 54: ...et that the bearing blocks often require no maintenance for the life of the machine Greasing Recommend One Pump 4 Times a Year Maximum Cross Section of Tapered Bearing Tapered Bearing FIGURE 3 6 Sample of Tapered Bearing Tapered Bearing Housings The taper bearings differ from other machine bearing assemblies in that they are in a sealed envi ronment To identify a Tapered Bearing Housing look at th...

Page 55: ...grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 80 hours of operation Ball Screw Nut Housing Ball Screw Drive Greasing Ball Screw Nut FIGURE 3 8 Example of a Typical Ball Nut Ball Screw Drive Assembly Including the Ball Screw Nut other types of bearings may be included on the assembly The figure below shows a typical Ball Screw Drive Assembly FIGURE 3 9 Ball Screw Drive Assembly Servo Moto...

Page 56: ...he door in and out of the machine Each pulley contains 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 ...

Page 57: ...he machine and follow the Lock Out Tag Out procedures Caution Servo Motor Drive Assembly Locations Use an extender to reach tight areas Make sure to Lockout Tagout before maintenance For rec omme E Adapter Needle Nozzle EP 2 Multi FAK Grease Grease Gun Extension Adapter Needle Nozzle nded greasing schedule see Lubrication Schedule on page 3 15 FIGURE 3 10 Top View of Commander III Outfeed Stop Ser...

Page 58: ...page 3 15 The Lock Location Servo Assembly is attached to the back section The Outfeed Stop Servo Assembly is located at the end of the machine on the inside front sec tion The Assembly is accessed by way of a cut out section on the frame FIGURE 3 11 Servo Motor Assembly Bearings Tapered Bearing Housing Recommend One a Pump4 X a Year Maximum Pillow Block Hub Style Recommended every 250 Hrs Ball Sc...

Page 59: ...e is located on the operator s side of the front section To maintain Clean area every day Lubricate the Hub bearings according to schedule Clean Chain with a dry silicon spray then wipe off with a dry clean rag according to schedule Check chain for sagging or tightness See Inspect Chains for Proper Tension on page 3 10 Note The front panel in the illustration below has been ghosted for display pur...

Page 60: ...ication Schedule on page 3 15 The illustration below shows the location of the Servo Assembly X Axis Y Axis and Z axis on the Cutter Head Use an extender to reach tight areas Tapered Bearing Housing Recommend One Pump 4 X a Year Maximum Pillow Block Hub Style Recom mended every 250 Hrs Ball Screw Nut Recommended every 80 Hrs Servo Motor Z Axis Servo Motor Y Axis Tapered Bearing Housing Recommend O...

Page 61: ...on Schedule on page 3 15 To get access to the bearings the Hinge Covers will have to be removed Cutting Head Base The Cutting Heads have many of linear bearings When greasing it can be helpful to group the bearings action Below is an isolated view of the Cutter Head Base with the Cutter Head Tool Box ghosted Cutting Head Y Axis Moves the entire head assembly in the Y axis direction 2 rails 3 beari...

Page 62: ...For recommended greasing schedule see Lubrication Schedule on page 3 15 Below is a view of the Cutter Head Tool Box with the Cutting Head Base ghosted Use an extender to reach tight areas Cutting Tools Z Axis Each tool moves into the cutting surface independently 1 rail 2 bearings per tool Cutter Box X Axis Moves the entire cutter head into cutting surface 2 rails 2 bearings per rail Cutter Box Z ...

Page 63: ...ckout Tagout before maintenance For recommended greasing schedule see Ball Rail Bearing on page 3 17 and see Pulley and Idler Shafts on page 3 20 Below is a view of the Back Section Assembly Use an extender to reach tight areas Lubricate Pulleys Vertical Ball Rail Bearings Set of two assemblies 4 Bearings 4 Rails FIGURE 3 15 Ghosted View of Machine Frame ...

Page 64: ...6 Ghosted View of Machine Frame Note Use an extender to reach tight areas In the illustration below machine assemblies have been ghosted for display purpose Lubricate Pulleys Clean and Lubricate feed system hex shaft with Silicon Spray Includes Hub Bearings on Axel Clean and Lubricate feed system hex shaft with Silicon Spray Includes Hub Bearings on Axel OutFeed InFeed The assembly is accessed by ...

Page 65: ...achine or Air prints to verify installation 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 17 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 observed through s...

Page 66: ...rmony 32 To prime the lubricator find an air line on the carriage section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose Repeat this same procedure for the back section and other trouble areas It is recommended to check t...

Page 67: ...afety guidelines described in Failure to do so can result in damage to equipment and or seri ous injury to personnel Caution This section 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 Chisels Pre Drill Bit Router Bit Counter Rotate Router Bit Chisels FIGURE 3 19 Location of Bi...

Page 68: ... FIGURE 3 20 Collet Assembly How to Access to Bit Assemblies 1 Shutdown the machine and follow the Lock Out Tag Out procedures 2 After machine is locked and tagged out loosen remove the screws from the Top Dust Cover Collet Spindle Collet Nut Verify that there is no damage or blu ing on the side of the collet ...

Page 69: ...ch collet assembly on to drill 3 Insert the new bit into the assembly 4 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 the Router Bit Depth Gauge PN 432 C to set the depth of the drill Note Make sure the arbor is not bottomed out in the back of the motor If it is ...

Page 70: ...the bracket bolts 2 per chisel that secure the chisels 3 Remove the bracket 4 Slide the old chisel out of the assembly Note the orientation of the chisel Note The bracket has a tight tolerance and is a tight fit You may have to use channel grips to remove the bracket FIGURE 3 23 Replacing the Chisels 5 Slide in the new chisels 6 Tighten bolts back and forth until the bracket is tight 7 Inspect and...

Page 71: ...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 continue 3 Inspect and clean collet assembly 4 Insert the new bit into the assem bly 5 Before tightening the collet assembly adjust the bit depth Bottom out the bit and pull the bit up about 1 4 6 Lightly tighten and torque to correct valu...

Page 72: ...the new bit into the assembly 5 Before tightening the collet assembly adjust the bit depth Bottom out the bit and pull the bit up about 1 4 6 Lightly tighten and torque to correct value For torque values See Collet Torque Val ues on page 3 38 Note Make sure the arbor is not bottomed out in the back of the motor If it is the arbor will not tighten and will damage the collet or other machine parts C...

Page 73: ...ial 792 Drill Gear box with Airmotor Option W4 Yale 80 7150 0047 010 Drill Gear box with Air motor Option W5 Corbin Russwin VT30458 Drill Gearbox with Airmotor 1 Loosen the lever on top of the Drill Assembly 2 Disengage belt by pushing the motor forward 3 Remove the two highlighted bolts Keep them for re install 4 Carefully remove the assembly 5 Insert the new assembly repeat steps 3 2 1 Secure re...

Page 74: ...es KVAL Commander III Service Manual 3 38 Collet Torque Values KVAL recommends torquing the collets Torquing adds consistency is important for repeatable machining Follow the torque tool manufacturers method of torquing ...

Page 75: ...Collet Torque Values 3 39 KVAL Commander III Service Manual ...

Page 76: ...Collet Torque Values KVAL Commander III Service Manual 3 40 ...

Page 77: ...tion control circuits Includes dia grams of the control circuits page 4 2 Troubleshooting Basics This section includes basic troubleshooting infor mation Includes analyzing sub systems to des ignate a starting point for troubleshooting page 4 4 Troubleshooting Electrical Problems Includes voltages in the electrical panels using the Status Light panel to troubleshoot and VFD troubleshooting page 4 ...

Page 78: ...oor out 6 Wait for the next door Point to Point Point to point motion control involves moving 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 Increment...

Page 79: ...e 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 dedicated motion control board Positioning System Moves the load Examples A motor or a pneumatic cylinder The Position Feedback Provides location information to the controller Examples A limit switch a photo eye or ferrous eye a resolver o...

Page 80: ...age 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 Shoul...

Page 81: ... circuit See Troubleshooting with the Status Light Panel on page 4 19 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 that motor runs without t...

Page 82: ... Voltage may cause personnel injury or death Troubleshooting 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...

Page 83: ...k diagram see Figure 4 27 on page 4 6 FIGURE 4 28 Sample of VFD 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 ...

Page 84: ... 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 th...

Page 85: ...gram of a Pneumatic Circuit PLC Output High Pressure 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...

Page 86: ... 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 operation button Manual Activate Button Push to toggle solenoid to the ON state activates if power is off Indicator a Lit LED indicates the solenoid is in use Red LED the A Port on a single valve If double valve Red L...

Page 87: ... is delivered to port B FIGURE 4 33 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 righ...

Page 88: ...The Cylinder and Router retract deactivating the Extend Sensor 3 When the Cylinder and Router are fully retracted the Retract Sensor is activated 4 The PLC senses the voltage from the Retract Sensor completing the process Positioning System Load Force Translated Positioning PLC Instructions Position Feedback Extend Sensor Retracted Sensor Deactivated Activated 24 Volts Extended Cylinder 24 V Appli...

Page 89: ...embly Load Position Feed Back Air In Control Valve Retract Sensor Activated Air Pressure Retracts Cylinder and Router Assembly RETRACTED Positioning System Load Force Translated Positioning PLC Instructions Position Feedback Extended Sensor Retracted Sensor Activated Deactivated 0 Volts Retracted ...

Page 90: ... feed problems far marks in the corners of hinge pockets and flipping screws in Hoppers However sometimes machine settling mechanics be broken in may be cause to slightly adjust extend and retraction speed If more than 1 2 turn on adjustment knobs are needed call in a specialist or check with KVAL customer service at 1 800 553 5825 Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Spee...

Page 91: ...to Eye 0VDC is sent to the PLC As a result any of the photo detectors output equals 0VDC when a door is sensed Some detectors have an emitter and receiver built in one unit such as an in feed sensor where a door blocks the light and reflects back to the unit Some detectors have an emitter and receiver built in separate units such as the through beam sensor set at a distance from each other If an a...

Page 92: ...s Switch Arm Using Sensors to Trouble Shoot Photo Sensors often 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 The distance from an e...

Page 93: ...hines 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 ar...

Page 94: ...ing with the Status Light Panel below for more information Note Most electrical problems are related to mechanical malfunction e g stuck motors jammed chain blocked photo sensors etc Note If a solenoid valve is suspected and not cleared in the air checks section see it can be electrically jumped to check operation 4 With the power off check for motor overloads by pressing each reset button usu all...

Page 95: ...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 4 20 STEP 2 Overload Relay Amber If light is OFF go to item B on page 4 21 STEP 3 E Stop Amber If light is OFF go to item C on page 4 21 STEP 4 Stop Amber If light is OFF go to item D on page 4 21 STEP 5 Start Amber If light is OFF go to item E on p...

Page 96: ...oing into the top of the Control Transformer replace the Control Transformer 6 If there is power at the Control Transformer check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip 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 ...

Page 97: ...op button to make sure it is all the way out and not stuck in then check the contact to make sure it is closed If still no voltage check the wiring Troubleshooting with the Status Light Panel 4 21 KVAL Commander III Service Manual 1 Check Motor Overload Circuits 2 With power on check the trip indicator LED on the overload If indicator is orange press the Reset Button to reset the overload circuit ...

Page 98: ...C 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 Ter...

Page 99: ...l See your machine s schematic package for detailed wiring information Connections to Servo Drives The Servo Drives are located in the Main Electrical Panel The outputs connect to the servo motors of carious assemblies They may include the Head X Y and Z motors feed motors back section location X Y and Z motors For detailed wiring information see your machine s electrical drawings Connections to V...

Page 100: ...Network System Overview KVAL Commander III Service Manual 4 24 ...

Page 101: ...ing lube3 15 DVI USB module location2 2 E EtherCat smart power supply2 2 terminals location2 2 ethernet module connection to servo amplifiers2 2 F flange block bearing maintenance schedule3 15 G gear box maintenance schedule3 15 general information about machine1 2 I inductive proximity sensor4 15 internet access location of connection2 2 remote connection2 2 RJ45 to intranet2 2 intranet RJ45 conn...

Page 102: ...n Off Sheet Safety Concerns1 21 sensors troubleshooing4 16 types4 15 voltage levels4 15 service connecting your machine to KVAL Service2 4 servo drives connections location4 23 start light description4 22 status light panel description4 19 use as troubleshooting key4 19 T tagout procedure1 10 troubleshooting using status lights4 19 TwinCAT 2 software automation software2 2 U USB module2 2 W Window...

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Page 104: ...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 ...