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1. KVAL 994 X Operation Service Manual 2 39 Diagnostic Screen 2 40 KVAL 994 X Operation Service Manual CHAPTER 3 Calibration of 994 X This chapter describes the steps to calibrate the 994 X Door Pre Hanging Machine Chapter 3 at a Glance PLOOUG CAMDEAUOMs serial ri ia tio riactads B tore you Calibrate maes Flow Chart of Calibration c ooccnnccnnccnniccnnoconoccnnoconoconaccnnocanincnnanonnss About the KVAL Calibration Routine ooccncccnnccnniccnnccnnnccnnacaniconancnnnoos Calibration Slot Drilling Specifications oooncccnnncnnnnnnnonnnnnnnnnnnnnonnnnos Run the Calibration Routine occcoccnncccnnccnnoconoccnnoconoconnncnnarcnnoccnnocaninonnss Selec nCalbratoOn smart aten Select Door Parameters arire a a Load the Door and Start the Cut ooccnnccnnccnnnccnncccnnoconoconaconnncnnaconnss About Motion of Servo Motors X Y Z and W occcccnccnccnccnccncnnnos Check Specifications of the Front Section occcccccccncnnnnocccnnnonnnnnonnnanonnnnss General Instructions to Adjust Parameters ooccccccccnnnnnnncccnnnnnnnnnnnnnnnn Step 1 Hinge Carriage Calibration ccccconnnncnnnnnnnnnnnnnnnnoncnnnnnnnononnnoos Step 2 Router CalipeaiOM ci anette set step o Pre DEl Cabral uns aa A Calibration of the Back Section oooocccccconnococnaconononcnacocnnnacrcacoroonunonns Lock Location Calibration oooocococncnncncnocnonocnononnononocnanncnonocnanncnaniono Fast and Slow L
2. Safety First Compliance with Codes and Regulations KVAL advises that you request an on site state safety review of your installation of this machine This is to ensure conformance to any additional specific safety and health regula tions which apply in your geographic area Other Hazard Control Action If you believe any part or operation of this machine is in Ret ak adl violation of any health or safety regulation STOP pro BOM Rest airt duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed safety guidelines are included in the operating instructions of this manual KVAL will be pleased to review with you any questions you may have regarding the safe operation of this machine Follow Your Company s Safety Procedures In addition to these safety guidelines Your company should have on site and machine specific safety proce operator mamasi betors dures to follow KVAL 994 X Operation Service Manual 1 7 Safety First Lockout Tagout Procedure This policy is required by OSHA regulation 1910 147 and Cal OSHA S SB 198 ruling of July 1991 Use the following lockout procedure to secure this machine while it is powered down During a lockout you disconnect all power and shut off the air supply Be sure to use the tagout guidelines noted below To Lockout the This Machine 1 Assess the equipment to fully understand all energy
3. Ud About the Setup Screens About the Pre Drill Screen From this screen you can adjust and store up to five pre drill screw patterns in memory Name the The X and Y valves are referenced off the bottom Template 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 See the figure below Imagine a graph over the Hinge The X and Y values in the graph are entered in the Sample Template screen shot below Note Never enter a negative number in the Y parameter The pre drill will try to drill off the door into the Delrin Eh Pc a E ns t Mirror Image of Jamb Parameters Entered Door Positive Direction X Zero aaao gt Point Sample of a common 3 5 inch and 4 inch hinge FIGURE2 17 Pre Drill Screen Description KVAL 994 X Operation Service Manual 2 35 About Manual Operation UMD About Manual Operation From this screen you can control certain functions of the machine in manual mode This screen is mainly used in troubleshooting checking cut specifications and maintenance Ok Ta Hara Randy te Hart HOME pecirnta Pa Ok Ta Homa Lath Routine Ready lo Homa liutoFerd OF Manual Feed Mode HI Ok To Home Ha Ok ToHame Width Adjus
4. Ses A r y ua F FIGURE 6 16 Bottom View of 994 X location of X Axis Sensors KVAL 994 X Operation Service Manual 6 13 Troubleshooting Electrical Problems Troubleshooting Electrical Problems Refer to Air and Electrical Schematics provided with delivery of the machine Schematics are located in the Electrical Panel If copies are unavailable contact the KVAL Service Department Have model number and serial number of machine readily available Warning The following checks require the electrical panel to be DM energized These troubleshooting checks must be per formed by a Qualified Electrical Technician NOTE The electrical component systems are designed to expedite the troubleshooting process and mini mize down time In general component systems have the input or feed functions at the top Output or load functions are positioned at the bottom Most two voltage electrical panels are designed with the LOW VOLTAGES on the LEFT and the HIGH VOLTAGES on the RIGHT The majority of the system components are labeled with numbers that correspond with the electri cal prints included in the electrical box door Computer controlled machines have signals on the computer that light up when the input or out put functions are energized respectively Computer controlled as well as non computer controlled machines have white 120V control power terminal strips This will indicate power supply from the re
5. Horizontal If the Horizontal time is not making it left or right before the vertical move starts enter 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 3 16 KVAL 994 X Operation Service Manual CHAPTER 4 System IT Administration This chapter describes the KVAL 994 X controller The controller is an on board computer that supplies the user interface and controls the operation of the machine With the controller KVAL can remotely help troubleshoot your machine Chapter 4 ata Glance System IT Administration 4 2 About the 994 X Computer 4 2 Connections on the PLC 4 2 Backing up the Computer 4 3 About Remote Connection to KVAL Service 4 3 4 1 System IT Administration UMD System IT Administration For optimum support the 994 X requires internet access With internet access KVAL Service Support will be able to access your machine through your company s Intranet and help solve any issues that may occur Connection to the Intranet is achieved by interfacing with the 994 X con troller The location of the Intranet connection is
6. Innovation Quality amp Honesty 994 X Pre Hanging Door System Operation and Service Manual Published 2 23 15 Proprietary Notice This Manual is confidential and contains proprietary information and intellectual property of KVAL Inc and is to be used solely by Customer as an operating manual for KVAL Inc machines Neither this Manual nor any of the information contained herein may be reproduced or disclosed under any circumstances without the express written permission of KVAL Inc For authorization to copy this information please call Kval Customer Support at 00 553 5823 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 Manual Part Number 204 OPSRV_994X V1 The 994 X Door Hanging System is a trademark of Kval Incorporated Copyright 2014 Kval Incorporated All rights reserved Beckhoff TwinCAT J and EtherCat are registered trademarks and are licensed by Beckhoff Automation GmbH Windows 7 is a registered trademark of Microsoft Corporation All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated Contacting KVAL Customer Service For further information about this manual or other Kval Incorpo rated products contact the Customer Support Department e Mailing address Customer Support Department Kval Incorporated 825 Petalu
7. 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 Note The figure shows the cover off for training purposes Changing the Bolt Drill as Use the shaft wrench and collet wrench to remove the bit on the pre drill or router assemblies See photo 2 Inspect and clean collet assem bly Figure 5 8 on page 10 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 Collet Wrench PN Note Make sure the arbor is not 15 00ER32 bottomed out in the back of the motor If 1t 1s the arbor will not tighten and will dam age the collet or other machine parts Shaft Wrench 1 5 8 KVAL 994 X Operation Service Manual 5 13 Replacing Bits Changing the Face Plate Router See Remove and Replace the Router or Pre Drill Bits on page 5 9 The motor and bits are the same configuration 5 14 KVAL 994 X Operation Service Manual Replacing Bits KVAL 994 X Operation Service Manual Replacing Bits 5 16 KVAL 994 X Operation Service Manual Co CHAPTER 6 Troubleshooting the 994 X This chapter describes troubleshooting steps to help technicians solve issues that may occur with your KVAL machine If help is needed call or contact our KVAL Service team at 800 553 5825
8. Overview of the 994 X Door Hanging SysteM ccocccccncconnneonnnnnns 1 2 ADQUITAIS ManUaluransncncara caia 1 3 Oa Gly FIS aran 1 4 Safety Sheet Sign Off SB ticccccccccononnnnenonnnconnnnnnonannnnnnannnrnnannrrnnanrnnnanns 1 4 Safety Terminology Of Labels srania ae aai 1 4 oale GUJENG nanei L 1 4 Lockout Tagout Procedures in 1 8 Follow the P R O P E R lockout rule Of thuUMb occccocncccnnnnconnannnnonannnos 1 10 Zero Energy 10 ota U Did 1 11 Zero Energy State to Start Up to Operating State cccccnccccncocannnonannnnnnas 1 11 Getting Help from KVAL tcscccssecceseccensecnseeeensenensesensesenseeseaees 1 13 On Line A a a 1 13 Proquict Return ProcedUTE soriana 1 13 sale SIOM Ol SM CCL ias 1 16 A Note to the Operatoria 1 16 Chapter2 Operation of the 994 X Operators TOUR assi 2 2 POOUL TING IIA dd 2 3 H Feed Section 2 3 EOS COLOM a 2 4 Operators olla dd 2 5 Machine GON TO casita iia 2 5 Narrow Door Support Option V ccccccccncnconannccnncnccnnnanonenannnennannnrnnannnnas 2 6 HINGS Gaiman a i 2 7 About The Six SNOOTE SYSTSM sieis a a aai 2 7 About the Six Shooter Controls cccccssssseccssseescenseessenseeseesseeseenseesonseees 2 9 ADOUNC IODC ica 2 10 A A aa Eear ei 2 12 About the Overhead Tra nicinoaca oiae nineio nena aaaea aa anaidai 2 14 About the Electical Panels wsccaveccaseetecrcttscauesdsbeuneressssaccseeedvebtocsxeteacane 2 17 Description of the Six Light Panel sssscssssecsssssesssseceeseeeeeseeseasessenees 2 18 ADOU
9. The company s lockout procedure should be posted at each machine On larger or long term mainte nance or installation projects the company s procedures must be explained to all new operators and a copy of the company s procedures should be posted on site for the duration of the work The Company s procedures should also include provisions for safely handling shift changes and changes in operators or new operators Comprehensive lockout tagout KVAL 994 X Operation Service Manual 1 11 Zero Energy to Start Up may use a gang box or other system to ensure that locks are secure and not removed without authorization Remember lockout tagout procedures work because you are the only one with the key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect 1 12 KVAL 994 X Operation Service Manual Getting Help from KVAL Getting Help from KVAL Before you seek help first try the troubleshooting procedures Follow the procedures below If you are unable to resolve the problem 1 Locate the machine s Specification Plate and record the serial number 3 phase volts electrical print number and air print number Serial
10. e The depth of the router should Hinge Depth Setting from the Operators Station e The length of the router should 1 000 the diameter of the bit e The width should the diameter of the bit e The slot should be centered in the H block and center on the thickness of the door Adjusting the Router 1 Run the Calibration Routine See Run the Calibration Routine on page 3 6 KVAL 994 X Operation Service Manual 3 11 Check Specifications of the Front Section 2 Check measure and calculate specifications of Router cut 3 To set a new reference go to the calibration menu and select Combine with Base 4 Enter calculations Router X If the Router cut position is to the right ds enter positive number If cut position is to E the left enter a negative number g0 000000 with Base Base Y If the Router cut position is high enter UE negative number If cut position is low enter 0 00000 Eno a positive number with Base ItIV u A SO 000000 Z If the Router cut depth is too deep enter DS j Combine a negative number If cut is shallow enter a 0 000000 eee positive number o AGREE bi Diameter Diameter The diameter menu allows Io 000000 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 Dase SODODOO FIGURE 3 8 Router Calibration Menu 5 Repeat until cut is center
11. 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 the arbor will not tighten and will damage the collet or other machine parts Drill Depth Router Depth Set to 2 0 Set to 1 3 4 20 13 4 Router Bit Depth Gauge FIGURE5 9 Setting the Bit Depths 6 Tighten the collet assembly 5 10 KVAL 994 X Operation Service Manual Ud Replacing Bits 7 Inspect and verify the work Clean the work area 8 If maintenance is completed replace dust cover and tighten bolts 9 orientation of the chisel Remove and Replace the Screwdriver Bits To replace screwdriver bits on the Six Shooter heads follow the instructions below 1 Turn off all power to the machine Follow proper lockout tagout procedures as detailed in the safety section of Chapter 1 of this manual 2 Disconnect air from Six Shooter using the air connect slide valves Slowly slide the valves back toward you listen for air to be released 3 Pull the Six Shooter assembly toward the machine it will move slightly 4 Locate the back slide near the air valves see images push slide away from you This allows for movement of the Six Shooter assembly away from the machine 5 Move the Six Shooter assembly away from the machine it will move about 1 inch This provides room
12. ii ising wacecedencees 6 22 INGIWOLK SYSTENMOVEIVICW id 6 23 Connections to Servo Drives asrivticidioiecinacicecniczeseneddiaant anionic seicmereraieeseees 6 24 Connections to VFD s High Freq Panel 6 25 Refer to the Air and Electrical drawings provided with delivery of the machine The drawings are normally located in the Electrical Panel If Note copies are unavailable contact the KVAL Service Department Have drawings numbers model number and serial number of machine read ily available 6 1 About Motion Control UD About Motion Control This section describes the positioning systems found in KVAL machinery There are three basic types of motion control methods used in KVAL Machinery Sequencing Sequencing 1s a series of events executed in a predetermined order Most KVAL machines use a form of sequential motion control A typical series of events for a KVAL machine are 1 Move the door into position 2 Clamp the door 3 Make the cuts 4 Unclamp the door 5 Move the door 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 1s limited by phys
13. on page 2 30 Additional Functions Operation Additional Functions Skip Hinge 1 4 Select to Skip the hinge route f and drill functions any hinge Test Mode Select to toggle the Test Mode on or off Test Mode runs the hinge cycle but does not extend the tools This is primarily used to ver ify a new template is correct and the hinge carriage will not bump into the H Block or other assemblies KVAL 994 X Operation Service Manual 2 37 About Manual Operation Burn Out Chip Operation Use this menu if a new Chipout Block is installed on the lock section or the hinge section Press the appropriate button to start the burn sequence a new hole will be slowly drilled the process will automatically stop when finished Jog Lock Location Jog Lock Location Use this menu to move the lock location on the back sec tion 8 Reset Button Press the Exit Application button to close the user screen and return MZ to the Windows desktop This can be used if the operator needs to Badae 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 out
14. or http www kvalinc com Chapter 6 at a Glance ADOUE MOON CONTOL sisii a r N 6 2 Basic Conto FC ICU senseri e sage Ncieae aa 6 2 Typical POsitionin Systems ds 6 4 Common Contactor COMTOL sa 6 4 Common Motor Drive Contool a a 6 5 Typical Positioning System Pneumatic Circuit cccccnnnnnnccccnnnnnnnononononinononnnnnnnnos 6 6 TrOUDIESHOOUNE Bastos baraerien a 6 7 Betore you AdJUStE a AS AAA aid eevee 6 7 A alyze Me SUD SYSTEMIS dida 6 8 sine Sensors to Trouble SHOOT aia 6 10 Locatton Or Sensor OI oi dad 6 11 Z Axis and Y Axis Front Section Sensors vitoria adas 6 12 MARIS SENSOTS PLONE SCCUOM a 6 13 Troubleshooting Electrical Problems siii 6 14 If the Power Stops During Normal Operation ooocccccncnnnnnnnnnnnicnnnnnnnnnnnonononannnnnnnnnnos 6 14 Troubleshooting with the Status Light Panel cccccncnnncoocnnnnncnnnnnnnnnnnnnnononnnnnnnnnos 6 15 Control PowerLight OPP a ccckcdcciaisiee Rides 6 17 Overload Relay Tent ORE a eta 6 18 F Stop Lash ORR a sc eu deed st 6 18 SIOPWLIGHE ORE dd casi iii 6 18 A a o tee cha Seats 6 19 ANDEAN att cae genet 6 19 About VFD TroubleshOOuUng ia do 6 20 Error Checking on the Variable Frequency Drives occccccccccnnnnnnnoccnnnnnnnnnnnnos 6 20 Usine the RessEDUMOnS ri ii 6 20 Troubleshootine the ATC YIMAES sieren a a 6 21 Adjusting Cylinder Extension Speed ooooccnccnnncncncnnncnnnonncnnnnnncnonononanaccnoncnccnnnnnnnnns 6 22 Adjusting Cylinder Retraction Speed
15. shut down system description user interface2 28 six light panel description2 18 sequence list2 18 slot calibration routine3 5 start light description6 19 start light description2 18 start machine button power up2 22 status light panel description6 15 use as troubleshooting key6 15 stop light description2 18 stop sequence button description user interface2 28 y tagout procedurel 8 troubleshooting air cylinders6 21 using status lights6 16 TwinCAT 2 software automation software4 2 U USB module4 2 user interface screens menu map2 25 V voltage levels sensors2 19 VTD location in high frequency panel2 17 W width adjust user interface description2 37 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 4 locations5 4 zero energy start up clean up1 11 inspectl 11 KVAL 994 X Operation Service Manual
16. 0014 07 15 29296 0 Pacho Hadd Manage Lock Manager initired 014 03 1009 94 600 Popper Somer op KCiytinden iniii OM OF Oe 608 Peppers ler ar Cylinder HOplindes inbilicad A a GUION EHHIS Pleppeee Casting Up Cylinder ECyliadas bnitliz ad Production Tracking Tools UU AAA Bieppes Doo Open Cynder EC yin baltilzad 001401 010 735 54 Hopper Up Olinda KCiyplinder Iniced 014 037 010 26 300 Sera Drive Pop Messi Esla Cemi dae 0140 03 0900 79 96 506 Screw Drbe in and Leck Cplindara KC plindor hiired D t ArH AM 50 feila Dikar Cytinde ECpfinder initilied 014 OF 79 560 Fight Shooter Blank initiis 01 01 0009 Hepper Sors hop RC ylindes rd 01 010 Peppers Hie Nar Cylinda Kylander Initlized 01 07 Hopper Casting Up Cliade ECpliadar bnltilrad 701407 0519 9 56 5607 Pepp oot Open Cada EC ylsdai Baiiia POUTI 09 79 56 560 Hopper Up Cylinder KCplicder letra 2014 03 19 00 79 54 560 Screw Debes Pomp Matar Eiaa ean iaiia 7014 03 19 09 354 5607 Loros Dress in and deck Clima KE plinder inira E T PET Goti 30S 560 Vertical Dutwar Cynder RC ylindar Initliced ATA Sees Posen iiiaae 560 ftis Shooter Kihlanki inated 010 07 79 76 SED PRight Chie Cylindes KC plindes Initliped GUIA AA 6 Lei Chine Cylinder Kyed hiire 9014 03 7G 5605 Ps hill Plunge Cylinder HCplindes Initiized 0140 19 AAAA SEN Mowee VE DY Motor Untied Bagi eh EE FIGURE2 20 Diagnostic Screen
17. 13 Block Diagram of a Pneumatic Circuit 6 6 KVAL 994 X Operation Service Manual Ud Troubleshooting Basics Troubleshooting Basics Good trouble shooting starts with looking at the whole machine where every part is suspect Then narrowing down the view to the bad part Ask Ask basic questions For example e What was the Machine Trying to Do e What Was the Machine Trying to Do Next e Was the machine working before e Did 1t happen on first power up or during process Narrow Narrow or determine the sequence and subsystem where the issue occurs For example e Did the issue happen when door was being fed in e Is the router not cutting e Is the cut out of specification Note See Table 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 e How is the subsystem supposed to work e What is keeping the subsystem from working Note See Analyze the Sub Systems on page 6 8 for information on verifying and analyzing subsystems Before you Adjust Sometimes simple problems can seem to be complex issues Before making adjustments check for the following common issues 1 Is the loaded setup correct for the current cut 2 Are the stops set up correctly 3 When did the problem first start e At first Start Up e During the Run 4 When was the last calibration 5 Is the door true 6 Use Router Bit Depth Gauge
18. 7 Once this number is added to the base double select the box that has 0 000 A calcu lator will be displayed Enter the offset in this box 8 Select the check mark to confirm this number and exit to go back to the Setup screen 9 Exit out of the Setup screen and rerun the Calibration test 10 Re measure the parameters of slot 3 10 KVAL 994 X Operation Service Manual Ud Check Specifications of the Front Section 11 If slot is not centered repeat the steps above until the slot is centered 12 After centering is achieved select Combine with Base to store the corrections Enter a positive number to move the Carriage Up Enter a negative number to move the Carriage Down 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 Z Axis select the appropriate Z menu fo 000000 f yarn with Base i to Offset i Base 000000 4 If the depth 1s too deep enter a negative number of the difference of the measured and the desired depth 5 If the depth is too shallow enter a positive number of the difference of the measured and the desired depth 6 Rerun tests until the correct depth is achieved Step 2 Router Calibration Once the Hinge Carriage is calibrated to the center verify the Router
19. Manual UD Zero Energy to Start Up Zero Energy to Start Up Zero Energy State to Start Up to Operating State Starting the equipment properly is just as important as the lockout tagout guidelines in terms of safety Start up Guidelines The following guidelines below should be followed to start the equipment Inspect The equipment must be inspected for proper adjustment before starting equipment Clean Up All materials and debris must be cleaned up Any combustible materials or old parts used during repairs must be cleaned up and or properly disposed of Replace Guards Replace all equipment guards If part of equipment cannot be properly adjusted after start up with guard on contact the KVAL Service team See Contacting KVAL on page 1 2 Check Controls Confirm that all switches are in the OFF position Please be advised that some com ponents of the machine may start automatically when energy 1s restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is started Perform Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the personnel alarm before starting the equipment If your operation is more complex your company s comprehensive safety procedure may involve additional steps You will need to ask your supervisor about these procedures
20. Mesra Ee Eara Select DOO PaAlaMelel S aries oad the Door and Slat the Cll celica About Motion of Servo Motors X Y Z and W eecscseceeceececceceeceecesceees Check Specifications of the Front Section ccseeeeseeeseceeeceees General Instructions to Adjust Parameters cccccccccccnnonnnnnenannnnnannnnnanenanas Step 1 Hinge Carriage Calibration ccssccccsseesesseecessecensecenseesensesoees step 2 Router GallbralON tina step 3 Pr Drill GaliDraliOn sc Calibration of the Back SectlON coccccccccncncononananenencncanananananencanan Lock Location Calibration cccccccccnononononanoncncnanancncncncncnrncnnnnananananananananas Fast and slow Lock Plate TM Chapter4 System IT Administration 994 X Door Hanging System System IEAdMMIiS tal Mariani 4 2 About the 994 K COMPUILCM sicewciecstenestacente cacdaseesweadceccecusdctutessnetaseneenucn es 4 2 Comecions on tHe PEG siie 4 2 Backing Up the Computer cccssssecceeseessesssescenseeseesseeseeaseseonseessenseesees 4 3 About Remote Connection to KVAL SerViCB oconccnconnononconcanonnanranonnonnnnos 4 3 Chapter5 Maintenance of the 994 X Maintenance scheduled aan 5 2 Dl sido 5 2 A 5 2 SIX MONT GHECKUDS ora 5 3 Lubrication RequireMentS cccocccccnonconnconnnconnrennnrennnenannrnnnrnannnonano 5 4 Linear Bearings Flange Bearing and Pillow BIOCKS oocccooccconnannnnnnonas 5 4 Gear Motor Lubrication RequiremeniS ccomcncconnoncocnnnnnccnnanorenannnrrnannrnnnan
21. PN 432C to check depth of Bits 7 Check tools for wear 8 Check back side of H blocks for sawdust build up which may affect depth KVAL 994 X Operation Service Manual 6 7 Troubleshooting Basics Basic Troubleshooting Steps Ask Determine Where What was the Machine Trying to Do The Sequence Step Where What Was the Machine Trying to Do Next the Failure Occurs Check the Sequences in the Table Below Narrow What Part of the Machine is not Working Check the Subsystems in the Table Below Determine What What Subsystem is Respon sible for the Failed Sequence Step TABLE 6 1 Typical KVAL Machine Sequence Typical Machine Sequence Responsible Subsystem 1 Move Door into Position Feed System 2 Clamp the Door Door Clamp 3 Make the Cuts Cutter Positioning Cutter Power 4 Unclamp the Door Door Clamp 5 Move Door Out Feed System 6 Wait for Next Door Feed System Verify Analyze the subsystem m How is the Broken Section Suppose to Work Check the Load Check the Position Feed Back Check the Positioning System What is Keeping the Broken Section From See Analyze the Sub Systems on P Wo rking ping page 6 8 Analyze the Sub Systems 1 Check the Load for mechanical issues e Is the Load bound up e Is there sufficient lubrication e Is it an alignment issue e Is anything damaged 2 Check the Position Feed Back e Does the Position Feed
22. 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 23 Preset Selection Button Group Pressing a preset button calls one of twelve presets stored in mem ory Pressing the Modify Preset button allows the operator to store the active Main Screen parameters After pressing the Modify Preset button 1 Select one of the buttons in which to save the parameters 2 Name it to an appropriate label 3 Select the save button to save to memory 2 28 KVAL 994 X Operation Service Manual Description of User Interface Screens e Door Spec Group Set the parameters for the door in the Door Spec group The settings include e Shows the preset setting that is running e Can enter a door thickness e Choice between two door thickness settings e Can Select Door Length e Can load 6 Shooter or 8 Shooter Option Hinge Spec Group Set the parameters for the hinges inthe f 3 5000 Y Hinge Spec group The settings includes f PRA Hinge ES 0 2600 e Router speed adjustment real time Pa adjust piaua 0 0970 MH e The choice of pre drill patterns 3 plea 0 6260 Ba e Can enable or disable hinges e Can select and change hinge parame ters e Can disable and enable hinge calibrations You ca
23. Sequence Feed in a door from the Door Feeder Insert a Jamb pressing it firmly against the jamb stop Holding the jamb in place with hands in the proper position press the Jamb Clamp foot pedal to activate the jamb clamps Caution Read the Hand Placement and Warning Stickers on the Machine While loading the jamb it is important to be mindful of the placement of your hands If hands are in the wrong place when the jamb is being loaded the jamb clamp could crush hands 2 20 KVAL 994 X Operation Service Manual Quick Start Press Start Sequence from the control bar to start the Start machining process The front section will start to Sequence machine the hinge pocked on the jamb and door The back section will machine the lock and lock plate E Ti Load the hinge on Six Shooter alignment plate with the hinge pin towards the top of the door and the counter sinks facing out The alignment plate is magnetic and will hold the hinge in place Use Six Shooter Caution Be prepared for the front section routers to move into position and begin routing as well as the back section routers lock bore and bolt drill Slide the Six Shooter over and position it into the H Block using the Ryertex guides 3 1 Press the Start Sequence button to move the Six Shooter into position and drop the screws The six shooter will snap into 1 place 2 When fully seated press the Insert Screw 2 Butto
24. Tells the machine s other subsystems when the move process is completed Examples A PLC or a dedicated motion control board a Positioning System e e Moves the load Examples A motor or a pneumatic cylinder The Position Feedback e Provides location information to the controller Examples A limit switch a photo eye or ferrous eye a resolver or an encoder KVAL 994 X Operation Service Manual 6 3 About Motion Control Typical Positioning Systems Common Contactor Control Unlike general purpose relays contactors are designed to be directly connected to high current load devices Contactors are designed to control and suppress the arc pro duced when interrupting heavy motor currents The figure below shows a block dia gram of a typical contactor circuit with typical voltages Should measure Should measure Line Control Voltage Control Voltage Voltage 24 VDC here 120 VAC here Power Should measure Line Voltage here PLC Fuse s SpE Should measure Power Input Control Coil Contactor 0120 VAC Input ON 0 il Line Voltage here Power Output DC Should measure Control Circuit lt 7 Line Voltage here Common Motor ON FIGURE 6 11 Block Diagram of a Common Contactor Circuit 6 4 KVAL 994 X Operation Service Manual About Motion Control Common Motor D
25. The 994 X will e Machine a hinge pocket on a door and jamb for up to 4 hinges Head Assembly e Drill pilot holes for the hinge screws Head Assembly e Apply up to 4 hinges Six Shooter e Attach the hinges with screws Six Shooter e Cut a lock and lock plate Back Section In Feed Section e Door is input from previous machine e Includes automatic door width adjustment e Door is feed through machine for processing e The door is automatically positioned while the operator loads and clamps the door and jamb Feed Motor Drives the Door through the machine a P A AA ld x Ela i FIGURE2 2 Key Assemblies on the In Feed Section Operator Controls Computer interface to Run Machine In Feed System Door Enters Machine here Sensors triggered and width is adjusted to door Hydraulic Tank for Six Shooter Sets and Lifts Six Shooter out of Hinge pocket KVAL 994 X Operation Service Manual 2 3 Operator s Tour Front Section The Front Section contains e Operator Station e Six Shooter e Machine Control e Hinge Carriages 1 through 4 Opt V Narrow Door Support Machine Control Operator Station Supports Doors under 16 0 for Six Shooter either Hinge or Lock Side Hinge Carriage Hinge Carriage Hinge Carriage Hinge Carriage 1 2 3 4 2 4 KVAL 994 X Operation Service Manual AL Operator s Tour Operators Station The Operator Station conta
26. To stop release the button Z Axis Speed 100 4 Speed Select the white box and enter the speed of the carriage The range is 1 to 100 Use the number pad to enter the desired speed and press OK when fin ished ae 0 speed 100 2 38 KVAL 994 X Operation Service Manual Ud Diagnostic Screen Diagnostic Screen The Diagnostic screen displays all the tasks the 994 X performs This screen can help with trouble shooting by associating the error code to machine sections or functions The top line will have the most current routine that is running If the machine issue can not be resolved call KVAL Inc 1 800 553 5825 Have any error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten down time 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 displayed in the Daily Door Count box This count can be reset with the Reset Count button tian Hara D a MAA lhi Os cabled Lock Heute Dinabled ewer OT Press thp GT SAT button to continus e D valblad don Disabled PC Diu bb land Pt Cowal Plata Rara Plis Tit gaii 9014 03 19 09 79 56 961 6 Codo File Manage KGC sde Flebdanages niad G01 OE 0197 51 10 Coda Fille angel RG Cda ilebanaged initl
27. X See Main Screen on page 2 27 See About Manual Operation on page 2 36 See About the Machine Calibration Screen on page 2 31 See Diagnostic Screen on page 2 39 Setup Menu Buttons a Pra Drill Catup See About the Pre Drill Screen on page 2 35 KVAL 994 X Operation Service Manual 2 25 Description of User Interface Screens Machine Feed Back At the top and at the bottom right hand cor gt ner of all user screens is status feedback Power Off Press the START button to continue information The information generated is Feet Disabled as follows Hi Disabled St Disabled 1 General Machine Status H Disabled 2 Disabled 2 H3 Disabled 53 Disabled 2 Front Section Status Lock Routine Disabled 3 Back Section Status Plate Reset Plate Tilt out 3 4 Current Servo Positions Currently Loaded Note Use this information to isolate issues if having problems nr eco E with the machine Cutout ODL_430_23x37 4 Lock HA 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 customer design wants To allow the operator to make changes to parameters turn the Set Up Lock to the On position When this key is in the Off position the parameters are locked out No changes to the parameter
28. and safety devices are installed 8 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put 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 Lockout Tagout Guidelines pa i e e Place a tag on all padlocks On a tag each Cam roel ay operator must put their own name and date k These locks are only to be removed by the cant person who signs the tag He oa e If more than one person is working on the 3 machine then each additional person places a ori poo lock and tag on each disconnect E a ay e Only each operator may remove their own lock and tag KVAL 994 X Operation Service Manual 1 9 Safety First Important When many people are all working on the same machine you will need a multiple lockout device such as the one shown here Follow the P R O P E R lockout rule of thumb asias Process shutdown AA Recognize energy type electrical pneumatic mechanical etc Ossis OFF Shut off all power sources and isolating devices er Place lock and tag AAA ENERGY Release stored energy to a zero energy state R 0o Recheck controls and test to ensure they are in the OFF state 1 10 KVAL 994 X Operation Service
29. for hands to access the screwdriver bit holders KVAL 994 X Operation Service Manual 5 11 Replacing Bits 6 To remove screwdriver 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 restore assembly to original start ing position Back Section Follow the instructions in this section to change the bits on th Bore Drill Bolt Drill and the Face Plate Router Caution Turn off all power to the machine Follow proper lockout tagout procedures as detailed in the safety section of Chapter 1 of this manual 5 12 KVAL 994 X Operation Service Manual Ud Replacing Bits Changing the Bore Drill mb Use the shaft wrench and collet wrench to remove the bit on the pre drill or router assemblies See photo When loosening the collet 1t may tighten up crack again and continue N Inspect and clean collet assembly Figure 5 8 on page 10 3 Insert the new bit into the assembly 4 Before tightening the collet assembly adjust the bit Collet Wrench PN Shaft Wrench depth Bottom out the bit and 15 00ER32 1 5 8 pull the bit up about 1 4
30. hinge side with the use of a side shim This shim is not included The controls include 3 knobs to raise the wheels and adjust the width to 12 0 14 0 and 16 0 Set the controls as shown below to the following order for the desired width Knobs 1 and 2 adjust the width Knob 3 raises the wheels 12 0 Inch 14 0 Inch 1 Push In 1 Pull Out 2 Pull Out 2 Push In 3 Pull Out 3 Pull Out 16 0 Inch 1 Push In 2 Push In 3 Pull Out To process doors it is recommended to manually put two doors with the same width side by side The second door will act as a shim and allow machining on both sides of the door lock and hinge pocket if desired It is important to keep the doors together try clamping the doors together mb 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 the doors and measure from the brass of the H block to the back fence of the machine 5 To allow room for doors to be fed in use manual width adjust width to the measurement plus 1 0 See Width Adjust Operation on page 2 37 6 Manual feed doors from the out feed to the door stop at the in feed 7 Align the doors of needed 8 Clamp door and jamb 9 Perform normal steps to machine the door s See Quick S
31. is turned to the ON posi tion 4 Switch the green CONTROL TRANS FORMER switch to the ON position It should light up 5 Push the green START MACHINE button to boot up the machine Note Boot up may take 2 to 3 minutes Start 6 All lights on the status light panel on the electrical box should be illuminated See Description of the Six Light Panel on page 2 18 Note If a status light does not turn on during the power up process see Troubleshooting with the Status Light Panel on page 6 7 for assis tance in identifying the issue 2 22 KVAL 994 X Operation Service Manual Powering Operations for the 994 X Home the 994 X The 994 X must go through a homing routine before any operations are performed The homing routine sets a zero reference from which the 994 X measures 1ts movement and cutting process If power 1s lost or the 994 X 1s re set the homing routine must be performed again to reset the zero reference Press the Home button on the Main Screen touch screen 1 The machine will move to the home position at the in feed end of the machine 2 The machine will then move to about the middle of its travel The 994 X 1s now ready for work How to Power Down the 994 X Stop Door Sequence Shut Down system Reset Machine 1 Select Shut Down System from the Main Screen to close operator interface program and shut down the operating system Note Make su
32. move across the machine Screw Tracking Gate Assembly Hopper Plate Assembly Opt Z Quick Change Dump Screw E Gate Pick Off i f Cylinder itp a Opt Z Quick Change Dump Screw Pick Cylinder and Off Slide Funnel Assembly Opt Z Quick Change Dump Plate Assembly Container Cylinder Track Wheels Screw Delivery Tubes Air Injected Hopper Cylinder Six Shooter Pivot Frame Interface Cylinder Six Shooter FIGURE2 8 Hopper and Frame Interface Important Do not adjust any of the Hopper air cylinders They are adjusted at the factory Any adjustment may cause timing issues with the operation of the Six Shooter If you think problems are being caused by the cylinders please contact the KVAL Service Department for direction 2 10 KVAL 994 X Operation Service Manual Operator s Tour 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 Process 1 Pour Screws into the Hopper Note The recommended maximum amount of screws a quantity of 600 2 The Hopper moves the Hopper Cylinders up and down at the start of the process This organizes the screws and delivers them to the Screw Tracking Plate 3 The Gate Assembly monitors the quantity of screws delivered to the to the Screw Tracking Plate Assembly 4 The screws are
33. operating practices this machine can hurt or kill you It s in your best interest to safely and properly operate this machine Personnel Safety Concerns e have been properly trained in the operation of this machine e will always wear ear protection when operating this machine e will always wear eye protection when operating this machine e will never wear loose clothing or gloves when operating this machine e will watch out for other people Make sure everyone is clear of this machine before operation e will always follow my company s safety procedures I have read and understand these guidelines Machine Safety Concerns e I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency e will make sure all guards are in place before operation e will turn off the compressed air before loading hardware staples screws etc e will turn off the electrical power for setup e If the machine should operate in an unexpected manner stop production I will immediately and notify a manager a supervisor or a qualified service technician I have read and understand this document and agree to operate this machine in a safe man ner as described above Employee Name print Signature Date Supervisor Safety Officer Trainer Name print Signature Date Note It is recommended you make a copy of this sheet for new operators I
34. positive number to move the lock towards the bot tom of the door left or a negative number to move the lock towards the top of the door right T 0 LH 5 Re run the lock cut ls lira Bal 000000 Measure again and repeat steps 3 to 4 until the center of the lock 1s 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 pe 00000 re it E Ea leal pioonaon KVAL 994 X Operation Service Manual 3 15 Calibration of the Back Section 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 make sure the flow controls are set properly Note Before adjusting the Slow Lock Plate Timing make sure the Fast Plate Routine 1s set properly adjusted If the settings are in Extend Time adjust the Slow Lock Plate Timing Slow Lock Plate Fast Lock Plate Timing Timing Vertical 1 50 Vertical Harzontal 3 00 SEIEN E 1 50 FIGURE 4 Fast and Slow Lock Plate Timing Menu Vertical If the vertical time is not making it up or down before the horizontal move starts enter a larger number This number is in seconds If there is a delay before the horizontal moves enter a smaller number in this box Continue entering numbers until timing is matched
35. stacked in the slots of the Screw Tracking Plate Assem bly 5 The Screw Pick Off Cyl inder moves the Slide Assembly to capture screws Six at a time T B r jes il Ni ee lt 6 Press Start Sequence on the Six Shooter Control panel to activate the Slide Assem bly to drop the screws into the Screw Delivery Tubes 7 Each tube has air 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 clear screws between the back door of the hopper and the slides 3 Once the Hopper is in the up position the door will open and the Hopper will cycle down quickly to throw the surplus of screws out the funnel container KVAL 994 X Operation Service Manual 2 11 Operator s Tour UD 4 Once in the back section 1s in the down position the front section Screw Tracking Assembly moves upward to drain the rest of the screws out of the hopper this will cycle one more time to clear the screws from the slides 5 Press the Reset button on the Six Shooter panel located mid machine on the front section 6 Fill the Hopper with new screws Driver Assembly The Driver As
36. which may affect depth Note KVAL recommends that a test door is machined first and checked for specifications before production is started If any cut parameters are inaccurate use the embedded calibration routine as a step to verify the validity of the test setup 3 2 KVAL 994 X Operation Service Manual O pra q pa 2 y O gt O Q lt Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the 994 X juaupedag SA az WAM DEJO HAY 0 HT E aD Towel 1000 AINSEIAN Lo Inpoug jeu iapun 4000 umy E PUL EY 100 fares UAW gsp vonposd anuuo TIA sanss UWL 40 mege nog 010198 1014335 34 Ha 20 HT 25407 5 LOE pp La jaj A er a N 1015 JONEXp eS 13dsuj pur ansa weed aiima H i ee paran 0 100g aunsRayy Whe ype Winky E 01 Sua 20195 341 351 ls 40471 LE Mb FRE JUBII 1650 145 SO WN po uny wes auIINoOY UOReIgeD qed MUSTO SOO 30 FIGURE 3 1 Calibration Process Flowchart 3 3 KVAL 994 X Operation Service Manual About the KVAL Calibration Routine UMD About the KVAL Calibration Routine The calibration routine creates a reference cut to check settings against a known good source The routine is used to verify the front section It routes a horizontal slot and drills a center hole at precise specifications Using these s
37. 4X ii eiii 2 22 Home IDA iaa a a 2 23 Howto Power Downthe 994 X a 2 23 Emergency Shutdown and Recovery eeeessssssssseessssssssssscerrresssssssseceressssssssecerereesss 2 24 Description of User Interlace Screens a 2 25 Screen Selection Menu Map sali 2 25 Machime Feed Back tido duna dra crol aiaa 2 26 Controlling Access to User SCTESHS od tas 2 26 DIAS CLEC ta iii 2 27 Aboue Sep SCREENS A ci 2 31 About the Machine Calibration Screen ooooooonnnnnnnnnncnnnnnnnocnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonos 2 31 About the Setup Hinges 1 4 Screens ias 2 33 About Me Pre Dr Seren ladies 2 35 ADO Manual Operation di aan ieee 2 36 Diagnose Seres iS 2 39 2 1 Operator s Tour Operator s Tour This section takes you on a tour of the 994 X Pre Hanging Door machine 994 X In Feed Electrical Panel 1 Operator s Station Valve Bank 1 Hydraulic System Air Tank Hinge Carriage 1 i cai Hinge Carriage a 2 i F rai Valve Bank 2 Front in Back Section Section Ra Lock Plate iat Assembly Hinge Carriage i wei P i a m 3 Air Input Fil ter Lubricator Hinge Carriage 4 Lock Bore Assembly Six Shooter 4 Router and Pre Drill in Head Out Feed Valve Bank 3 Electrical Panel 2 Hopper FIGURE2 1 Identification of Key Assemblies of 994 X 2 2 KVAL 994 X Operation Service Manual AL Operator s Tour About the 994 X
38. Back agree with the Load position 6 8 KVAL 994 X Operation Service Manual Troubleshooting Basics In other words are the correct photo eyes limit switches or ferrous sensors acti vated Check the controller inputs to insure the proper 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 e Photo Eye Bad element or bad cable e Limit Switch Stuck or failure e Wiring Broken worn insulation e PLC Bad input port 4 Check the Positioning System Follow the circuit from the Controller output to the Load and check for component failures KVAL 994 X Operation Service Manual Using Sensors to Trouble Shoot Using Sensors to Trouble Shoot e Photo Sensors often get dirty Make sure they are clean If they are not clean debris blocks the signal e Check output voltages of the sensors in the active mode The voltage should effec tively equal 0 VDC e Check the output voltages of the sensors in inactive mode The voltage should effec tively equal 24 VDC 6 10 KVAL 994 X Operation Service Manual Ud Location of Sensors on 994 X Location of Sensors on 994 X Figure 6 14 below shows the sensor locations on the 994 X The T designation represents an input to the PLC and the Q designation represents an output from the PLC Door Sense Eye Narrow Doo
39. LC Ether CAT Output 24 VDC Input 3 ci rE a gt ber a High Voltage Servo Drive 7 Input 1 High Voltage Output Servo Drive 1 Servo Drive 6 2 High Voltage Outputs Servo Drive 3 2 High Voltage Outputs 2 High Voltage Outputs Servo Drive 2 2 High Voltage Outputs Servo Drive 4 2 High Voltage Outputs Servo Drive 5 2 High Voltage Outputs FIGURE 6 19 Servo Drives 6 24 KVAL 994 X Operation Service Manual Ud Network System Overview Connections to VFD s High Freq Panel The Servo Drives are located in the Main Electrical Panel The outputs connect to the following For detailed wiring information see your machine s electrical drawings lo AA VFD 1 Hinge Router 1 A Toh E VFD 2 Hinge Router 2 VFD 3 Hinge Router 3 VFD 4 Hinge Router 4 i a F y I i a E ia a y mM a a y E i i gF VFD 5 Face Plate Router VFD 6 Feed Motor i a i Al Y VED 7 Width Adjust j VFD 8 Pre Drill Router 1 VFD 9 Pre Drill Router 2 VFD 10 Pre Drill Router 3 VFD 11 Pre Drill Router 4 KVAL 994 X Operation Service Manual 6 25 Network System Overview 6 26 KVAL 994 X Operation Service Manual INDEX Numerics 110V 24 V terminals location electrical panels2 17 994 X description of machine2 2 A additional functions user interface descriptions2 37 adjustment menus how to use3 8 air input sy
40. Number 3 phase volts Electrical Print Air Print 2 Contact our customer support team e In the U S and Canada call 00 553 5825 or fax 707 762 0485 e Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 e Email address is service kvalinc com e Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday On Line Help On machines with a Beckhoff PLC and an internet connection our service team are able to con nect run and troubleshoot your machine Ask about this procedure when calling are service team See Chapter 3 System IT Administration on page 3 1 for more information Product Return Procedure If you ve contacted Kval for help and it is determined that a return is necessary use the procedure below to return the machine or part Note Non Warranty returns are subject to a 15 restocking charge 1 Obtain the packing slip and or invoice numbers of the defective unit and secure a purchase order number to cover repair costs in the event the unit is determined to be out of warranty KVAL 994 X Operation Service Manual 1 13 Getting Help from KVAL 2 Reason for return Before you return the unit have someone from your organization with a technical understanding of the machine and its application include answers to the following questions e What is the extent of the failure reason for return What are the relevant
41. 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 gram below MAIN ELECTRICAL BOX FRAME REMOTE 1 0 ml 5 3 T L EA atelier EE A tiger A E EERE Exito EI HAT EEE E p bhk Bh N IN eT eT DUT EECHHOP GEG Ah be a SSS See __ _ _ _ j Frame Remote Back Section Remote FIGURE 6 18 Network Connections Block Diagram KVAL 994 X Operation Service Manual 6 23 Network System Overview UMD Connections to Servo Drives The Servo Drives are located in the Main Electrical Panel The outputs connect to the following e Servo Drive 1 Head 1 X axis and Y axis servo motors e Servo Drive 2 Head 1 Z axis and Head 2 X axis servo motors e Servo Drive 3 Head 2 Y axis and Z axis servo motors e Servo Drive 4 Head 3 Y axis and Y axis servo motors e Servo Drive 5 Head 3 Z axis and Back Section X axis servo motors e Servo Drive 6 Back Section Y axis and Z axis servo motors e Servo Drive 7 Back Section Location and Feed Motor For detailed wiring information see your machine s electrical drawings Ether CAT Input From P
42. SONAS Sui 2 19 A ueneecsaree 2 20 KVAL 994 X Operation Service Manual Powering Operations for the 994 X ccccconcconnnonncoanncanrcanrnonnnonanos How to Power Up the 994 X cccoccccononanonananonancnnnnaconananonanrnnananenanaranananas HOME Me IIA ina How to Power Down the I94 Xocccoccnconcnonaconanononaronnarnnnannnnannanaronnnnnanenas Emergency Shutdown and Recovery cmomncccnnanonennnnonenannnrnnaanennnannnenananns Description of User Interface ScreenS ccccccconcnonnnonnnonnncnnnennnonns Screen Selection Menu MaPeccccocnnccccnnnnnccnancnnnnnnnnnnnannnnnnanerenannnrnnnannnnns Machine Feed BACK AAA A Controlling Access to User ScreenS cccccccccnncnonannnennnnnnrnnanenenannnnrnannnnnas A EA EE A E E TE About the Setup Screen About the Machine Calibration Screen cccscecececeececececececnenenscecececeeeees About the Setup Hinges 1 4 ScreenS ssssecsssssecessnsscsseseeecsenseesenereeeans About the Pre Drill Screen ccocccocccnconoconncnconanonannnnnanananananananananananenanans ADOUL Manual OPS Nasa PIAGNOSUC Screens Chapter3 Calibration of 994 X AOOUL Call Ol all ON A AP Before Vo Gallbralterarauan in sboner iets wandsnives FOW Chart or Galbraton a ire About the KVAL Calibration ROUuUtING ocococccnonononononocncnnnnnononnnnn Calibration Slot Drilling Specifications comcccccoonnnoccnnanonnnanonenannnrnnaannnnas Run the Calibration ROUTING ccccccecececcncececencscscenencsceneneseeneness Selec GS AID All O
43. ack up your data The data 1s stored in a backup folder in your Windows directory It is recommended to set up a back up schedule to save your data on a regular occurrence The KVAL service team would be happy to help If any questions occur contact our service team at 800 553 5825 or at www kvalinc com About Remote Connection to KVAL Service Remote access 1s a powerful tool to help fix issues that occur with the 994 X machine With the remote access our KVAL service technician 1s able to observe your user screen in real time read and adjust programming code For 994 X access a separate computer must have Beckhoff soft ware installed that 1s connected to the Intranet connection on the machine controller KVAL 994 X Operation Service Manual 4 3 System IT Administration 4 4 KVAL 994 X Operation Service Manual CHAPTER 5 Maintenance of the 994 X This chapter describes preventative maintenance steps for KVAL 994 X The content is geared to guide technicians to keep a regular maintenance schedule for your KVAL machine Keeping your KVAL machine maintained is an important piece for successful operation of your door production process Chapter 5 at a Glance Maintenance schedule ita diia 5 2 DAT rra ace caos 5 2 Weeki ica 5 2 SIX Momt CheECckUpS a oia 5 3 Euibacation Requirements sde ais 5 4 Linear Bearings Flange Bearing and Pillow Blocks ooooonnnnnnncc 5 4 Gear Motor Lubrication Req
44. al contains operation information and service and maintenance information It includes identification of machine assemblies power up and power down steps and informa tion about using the user interface The Troubleshooting and Maintenance sections are directed toward qualified service technicians TABLE 1 1 994 X Operation and Service Manual 204 OPSRVDOC_994x KVAL 994 X Operation Service Manual 1 3 Safety First UMD Safety First This machine is a powerful electro mechanical motion control system You should test your motion system for safety under all potential conditions Failure to do so can result in dam age to equipment and or serious injury to personnel Safety Sheet Sign Off Sheet At the end of this chapter there is a safety sign off sheet It lists personnel and machine safety cri teria to understand before operating the machine It is highly recommended that personnel operat ing working on a machine meet the criteria listed in this sheet It is recommended the sheet be signed and kept for records See Safety Sign Off Sheet on page 1 16 Safety Terminology of Labels In addition to the nameplate KVAL machines may have other warning labels or decals that pro vide safety information to operators Safety labels should be clearly visible to the operator and must be replaced if missing damaged or illegible There are three types of warning labels or decals e DANGER means if the danger is n
45. ate all slides and cylinder rods with dry silicone spray e Tighten all bolts e Backup computer software See Backing up the Computer on page 3 3 e Lubricate linear bearings and chrome shafts with silicone KVAL 994 X Operation Service Manual 5 3 Lubrication Requirements AVAL Lubrication Requirements This section describes the parts of the machine that require periodic lubrication and specifies the lubricants In addition it explains how to maintain the lubrication systems on the machine Linear Bearings Flange Bearing and Pillow Blocks If the bearing is equipped with a grease fitting Zerk Fitting 1t should receive Gram one pump from grease gun of Dura Lith Grease K VAL P N Lube EP 2 every 250 hours of operation Note Bearings without grease fittings have been pre lubricated at the factory and do not require further lubrication Zerk Fittings Zerk Fitting Location Depends on Position of Slide FIGURE 5 2 Zerk Fittings 5 4 KVAL 994 X Operation Service Manual Lubrication Requirements Gear Motor Lubrication Requirements Oil change is recommended after 2000 operation hours of operation Use AGMA 8 gear lube or MOBILUBE HD 80 W 90 or equivalent Ball Screws All ball screws should be lubricated Dura Lith Grease KVAL P N Lube EP 2 for every 80 hours of operation At each lubrication grease should be pumped into the fitting until clean grease comes out around the
46. ball screw Ball screw lubrication points End Bearing End Bearing Ball Screw Ball Nut FIGURE 5 3 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 lubricator located after the CDA filters delivers the lubricated air to valve banks and air cylinders Shop Air Input Lubricated Air Output Air On Off Knob Lubricator Muffler Filter Ter 3 Pressure Gauge with adjust Clean Dry Air CDA to purge Air Blow Off FIGURE 5 4 Typical Air Line Filter and Lubrication System KVAL 994 X Operation Service Manual 5 5 Lubrication Requirements Adjusting the Air Line Lubricator Using the knob on the top of the lubricator adjust until one drop per every other cycle is used as observed through sight glass Sight Glass When the oiler has run dry Top of Lubricator open the knob all the way until flow begins Once you have a steady flow tighten knob back down until you have one drop per every other cycle Drop will form at end of cane shaped tube visible inside glass Priming the Air Line Lubricator New and used machinery run out of oil from time to time It is a good practice to check your machine
47. chine General Instructions to Adjust Parameters From the Main Screen select Setup Setup Hinge 1 2 or 3 to get to the Hinge Setup screens See About the Setup Hinges 1 4 Screens on page 2 33 for further detail are Es ls Main Cal Main Setup Hinge 1 Manual Setup Hinge 2 Setup Setup Hinge 3 Diagnostics Wel Setup Hinge 4 Pre Drill Setup FIGURE 3 4 Path to Setup Hinge Screens Located in the setup screens are adjustment menus In these menus you can add negative or posi tive adjustments to move a cutting assembly to the desired position Enter the data in the white 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 About Motion of Servo Motors X Y Z and W on page 3 7 for information on direction of servo motors Title of assembly to adjust gt Hinge Carriage Enter Type in measured X Axis data 0 000000 RE SODOOO Parameter to adjust X Y and_or Z axis Offset Select this button to add or subtract the measured numbe entered Base Keeps a Running Total of measured numbers entered Combine with Base Combine Base Select this button at start of adjustment to set a reference and end of adjustment to store it to Of
48. d Y Axis Front Section SCNSOSS cccococorononononenencananananananananens 6 12 X AXIS Sensors Front SeclONiiaia iii 6 13 Troubleshooting Electrical ProblemS ommcocccconnnenonennnonanrnnanonnas 6 14 If the Power Stops During Normal OperatiON ccoccncconncnncconcnnnenannonenanas 6 14 Troubleshooting with the Status Light Panel ssssecsssseessesseeseeees 6 15 ADOUL VFO TROUDIESNOOUING ricino aain 6 20 Troubleshooting the Air CylindeFS cccconnccnoconcnnaconnancnnnnnonannnnnanonas 6 21 Adjusting Cylinder Extension SP e ssscsssssecssssseecesseeseeesseseenseesenaes 6 22 Adjusting Cylinder Retraction Speed ccccccseesseeeeeeeseeeeeenseeeseeeneeseens 6 22 Network System OVeIViOWennnccocncconcconncconnrnnnnrnnanenannrnnnrnananonano 6 23 Connections to Servo Drives ccccccccconnnnncccnancnnnnnnnonnnannnrnnanerenannnrrnannannas 6 24 Connections to VFD s High Freq Pannel ssscccsssseessesseeseesseeseeseeeees 6 25 994 X Door Hanging System CHAPTER 1 Introduction to the 994 X Door Hanging System This chapter provides an overview of the KVAL 994 X Door Hanging System and important safety information to follow when operating the machine Chapter 1 ata Glance Chapter catalanes isaac 1 1 Overview of the 994 X Door Hanging System oocccccnccnnnnnnninnnnnnnnnonononinnnnnnnnnnnos 1 2 ADOUR Manal ee aia 1 2 Sale PIGS OS rr is 1 3 Salely Sheet Sien Ole SNC iria aio sida 1 3 Salety Lerminolwoey O Labels india seeds Rie
49. e opposite is true for the retract motion 1 Check the air pressure to the machine 2 Check the flow controls to see that they are adjusted correctly and to the proper specifications 90 Degree Flow Controls Air fow adjustment screw Ti Restricted Air Flow Loosen Thumb tightening lock mut Ar acjuatind Pur a Sora Air Hose Connector Straight Flow Controls Air flow adjustment screw Oj Uy PENOSO aaj gt ad mi JM Nt z s en Thumb thahiening beck mut Note The End that iS Balore adjusting Ah read A closeat to the air flow n Free Flos In 3 Check for any obstructions to the cylinders such as Manual over screws or a misplaced tool etc FOLLOW ALL 4 ride button SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS KVAL 994 X Operation Service Manual 6 21 Troubleshooting the Air Cylinders 4 Check the solenoid air valves i Once activated The valve will allow full pressure to Caution cylinder Make sure you are clear of all moving parts a The solenoid valves can be manually operated by pushing the red manual override button on the end of the valve b If the valve seems to be leaking the seals may be dry or contaminated with water or it maybe that the cylinder O rings are damaged and air is passing from one side to the other side of the cylinder which means the air is exhaust ing through the solenoid valve It maybe is necessary to purchase a rebuild kit
50. each hinge location 4 The operator a places a hinge to the magnetic indexing fixture b rolls the Six Shooter over to the hinge location and pivots it into the H block c drives all six screws into the door and jamb d presses the Reset switch then raises the Six Shooter and retracts screw driv ers out of the pocket Hopper Screw Delivery Hoses te Operator Controls i 4 dy Magnetic Indexing Fixture Hinge is Placed Here Drive Assembly e Air Motor e Gearbox e Six Screw Driver Bits FIGURE 2 6 Photo of Six Shooter on the 994 X KVAL 994 X Operation Service Manual Ud Operator s Tour About the Six Shooter Controls Load Unload If equipped with quick dump hopper OPTIO Clear Screws Z this button would be used to operate this If screws get jammed in the six shooter optign press to clear the line Pull away from the machine and press the button cause air blasts in the line Reset Unclamp Reset raises the Six Shooter puttin all the cylinders back in the Start position NOTE If tilt cylinder is set to retract too fast it can cause the Six Shooter to jump out of the pocket and bounce on the top rail Allows the operator a choice to release the door either from a foot pedal or a Six Shoote mounted mushroom button Insert Screw When the Six Shooter is in the pocket position and the operator has inserted a hinge into the screw receiver block hin
51. ed 6 Select the Combine with Base button to finish 7 Repeat until cut is centered 8 Click Combine with Base to finish Step 3 Pre Drill Calibration Verify the Pre Drill e The depth of the pre drill should be 0 250 deep e The hole should be centered in the H block and center on the thickness of the door Adjusting the Pre Drill 1 Run the Calibration Routine See Run the Calibration Routine on page 3 6 2 Check measure and calculate specifications of Pre Drill cut 3 To set a new reference go to the calibration menu and select Combine with Base 3 12 KVAL 994 X Operation Service Manual Check Specifications of the Front Section 4 Enter calculations X If Pre Drill hole position is to the right enter positive num ber If hole position is to the left enter a negative number Y If Pre Drill Hole position is high enter negative number If hole position is too low enter a positive number Z If the Pre Drill hole is too deep enter a negative number If hole is too shallow enough enter a positive number FIGURE 3 9 Pre Drill Router Calibration Menu Pre Drill X Axis 0 000000 Base 5 el AE Y AxIs 0 000000 Base O CODOdI Z Axis 0 000000 Base O CODOd 5 Repeat until hole is centered 6 Select Combine with Base to finish Combine with Base Combine with Base Combine with Base KVAL 994 X Operation Service Manual 3 13 Calibration of
52. ed system timing description2 32 flange block bearing maintenance schedule5 2 front section key assemblies2 7 front section status feedback2 26 G gear box maintenance schedule5 2 H H Block calibration slot location3 5 high frequency panel description2 17 high voltage electrical panel2 17 hinge calibration user screens3 8 hinge carriage adjusting the X axis3 9 calibration3 9 sample of X axis adjust3 10 user interface discription2 34 hinge spec group description2 29 home button description user interface2 28 using2 23 l inductive proximity sensor2 19 in feed section key assemblies2 2 input and output terminals location electrical panels2 17 internet access location of connection4 2 remote connection4 2 RJ45 to intranet4 2 intranet RJ45 connection4 2 J jamb insert into machine2 20 L LCD display smart power supply4 2 linear bearing maintenance schedule5 2 lock calibration3 15 lock access to user screens2 26 lock location adjusting location3 15 lockout and tagout Guidelines1 9 lockout procedure1 8 M machine calibration group description2 32 machine feed back user output2 26 machine feedback front section status2 26 general2 26 servo positons2 26 machine status general feedback2 26 main cal screen group locations2 31 main electrical panel description2 17 main screen interface2 27 maintenance daily5 2 six month5 2 weekly5 2 manual operation interface2 36 manual screw insert user inter
53. elect the check mark to confirm this number and exit to go back to the Setup screen 10 Exit out of the Setup screen and rerun the Calibration test 11 Re measure the slot 12 If slot is not centered repeat the steps above until the slot is centered 13 After centering is achieved select Combine with Base to store the corrections KVAL 994 X Operation Service Manual 3 9 Check Specifications of the Front Section Enter a positive number to move the carriage left Enter a negative number to move to the carriage right FIGURE 3 6 Samples of X Axis Adjustments Adjusting the Y Axis 1 Run the Calibration Routine See Run the Calibration Routine on page 3 6 Use the H Block as a reference to determine the vertical center of the calibration slot Figure 3 7 on page 3 11 shows an example of high and low off centralizations 2 Measure the amount of material left between the Actual Door 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 Combine screens 0 000000 5 Locate the appropriate Menu in the Setup interface SaaS to Offset Ease DODOD 6 If there 1s a number in the box under Y Axis select the Combine with Base button to Set a reference
54. equency Panel e Supplies voltages to the machine e Supplies voltages to the machine e Contains the PLC Programmable e Contains the PLC interface Logic Controller VFDs Variable Frequency Drives to Contains servo drives to interact with interact with hinge and faceplate rout the servo motors Axis and Lock Loca ers width adjust motors and feed tion in the front and back sections motors Warning High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off If working on the panel follow the safety protocol as described in Chapter 1 Main Electrical Panel High Frequency Panel PLC and Power estes R PLC Interface Supplies 110V 24V Terminals 110 V 24V Terminals High Voltage Section High Voltage Section Input Output Input Out Terminals put Terminals Servo Drives VFD Section zJ FIGURE2 12 Overview of Main Electrical Panel and High Frequency Panel KVAL 994 X Operation Service Manual 2 17 Operator s Tour Description of the Six Light Panel The six lights on this panel indicate the status of the 994 X system The Sequence that the lights activate is as follows 1 Control Power 2 Overload Relay 3 E Stop 4 Stop 5 Start 6 24VDC Stop This light will be on if Machine Stop button is deac tivated Control Power light illuminates when the Control Transformer is pulled out and the pow
55. er is working on secondary side of transformer o Start This light will be on once the Machine Start button is pressed and the ACR Relay is latched Overload Relay The overload circuit is working when light is on 24VDC light E Stop The back comes on once the gate is closed and Frame E stop is not acti ACR is latch and the vated when this light IS On 24VDC power Supply is working 2 18 KVAL 994 X Operation Service Manual Ud Operator s Tour About Sensors On the 994 X sensors provide input to the PLC as part of the automation of the door cutting pro cess It is important to keep the sensors cleaned and aligned to keep the door process running smoothly There are two classifications of sensors on the 994 X Photo Electronic and Induc tive Proximity Sensor The Photo Electronic Decor uses light as a trigger e Photo Eye Detectors contain both emitter and receiver If an object is within the Photo Eye s sensing field light from the emitter is reflected from the object back to the receiver With no object is in front of the Photo Eye a constant 24VDC is sent to the PLC If an object is sensed by the Photo Eye OVDC is sent to the PLC e As aresult any of the photo detectors output equals OVDC when a door is sensed The Proximity Sensor detects metallic objects without touching them e An inductive proximity sensor consists of a coil and ferrite core arrangement an oscillator and de
56. error mes sages or error codes e How long did it operate e Did any other items fail at the same time e What was happening when the unit failed e g installing the unit cycling power starting other equipment etc e How was the product configured in detail e Which 1f any cables were modified and how e With what equipment is the unit interfaced e What was the application e What was the system environment temperature spacing contaminants etc 3 Call Kval customer support for a Return Material Authorization RMA When you call e Have the packing slip or invoice numbers available e Have the documented reason for return available 4 Send the merchandise back to Kval e Make sure the item s you are returning are securely packaged and well protected from shipping damage e Include the packing slip or invoice numbers e Include the documented reason for return e Include the RMA number with the parts package 1 14 KVAL 994 X Operation Service Manual Getting Help from KVAL Page Intentionally Left Blank KVAL 994 X Operation Service Manual Safety Sign Off Sheet Safety Sign Off Sheet Machine Model Number A Note to the Operator This machine can help you be highly productive only 1f you understand how to use 1t properly and follow the safe operating practices described in this document and the machine s manual If you do not understand the machine s proper operation or ignore the safe
57. es 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 Router Bit Drill Bit FIGURE5 6 Location of Bits in the 994 X Heads 5 8 KVAL 994 X Operation Service Manual Ud Replacing Bits 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 3 Fold back cover to access the bit assemblies Remove and Replace the Router or Pre Drill Bits After lockout tagout and access has been obtained to the assemblies follow these instructions to remove and replace the router bit or the pre drill bit 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 17 mm Shaft Wrench FIGURE5 7 Removing Pre Drill or Router Bit 2 Inspect and clean collet assembly KVAL 994 X Operation Service Manual Replacing Bits Collet Spindle Collet Nut Verify that there is no damage or bluing on the side of the collet FIGURES 8 Collet Assembly 3 Lightly attach collet assembly on drill 4 Insert the new bit into the assembly 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
58. f a copy is needed you may download a PDF at the KVAL website http www kvalinc com You may also contact our Service Department at 800 553 5825 or email at service Okvalinc com 1 16 KVAL 994 X Operation Service Manual Safety Sign Off Sheet KVAL 994 X Operation Service Manual Safety Sign Off Sheet 1 18 KVAL 994 X Operation Service Manual Co CHAPTER 2 Operation of the 994 X This chapter describes components assemblies and the user interface of the KVAL 994 X Door Hanging System The content 1s geared to help operators understand the basic operation of the 994 X Included are instructions to calibrate the machine and process a door Chapter 2 ata Glance Operators OU as EA a At tla dallas 2 2 ADONCA IATA edi recae tienda 2 3 In Feed Secun a iaa 2 3 FOES CO a E 2 4 Operators DANON ei 2 5 Machme Control a tac 2 5 Narrow Door Support Option V riada 2 6 Hn Cao ooo 2 7 About the Six Shooter System on ccccccccccsdsscesssiscccdeacntesessedensssetecranncesesedacesaccacesecdasees 2 7 About the Six Shooter Controls ii A ea eae 2 9 FXDOUCINE IOP DEE ud 2 10 Driver Assembly iii adeeb dee 2 12 Aout tine OVerMeadTEACK ias 2 14 About the Electrical Panels ui ida 2 17 Descriptiomor the six erent Panel li 2 18 ADOUESCASDES vd ali data 2 19 A SUNG sitet uagios saat A N se 2 20 Powering Operations for the 994 X oie taerien eneee o eE E T ETE Ea ote 2 22 How to Power Up the 99
59. face descriptions2 38 menu map2 25 KVAL 994 X Operation Service Manual N network system overview6 23 O offset button how to use3 8 operators tour top view2 2 out feed key assemblies2 16 overload relay light description2 18 P pillow block bearing maintenance schedule5 2 PLC battery location4 2 connections4 2 location4 2 location in main electrical panel2 17 power disconnect switches1 8 lock out procedure1 8 power up troubleshooting6 14 powering up and down machine2 22 pre drill calibration3 12 user interface description2 34 pre drill bit using tool to set depth5 10 5 13 pre drill bits replacing5 9 preset selection description2 28 product return procedurel 13 programmable logic controller PLC4 2 R reset machine button description user interface2 28 return material authorization RMA 1 13 returning the product to Kval1 13 right hand door KVAL 994 X Operation Service Manual selecting2 20 router calibration steps3 11 router bit replacing5 8 S safety guidelines1 4 Safety Sign Off Sheet Safety Concerns1 16 screwdriver bits remove and replace5 11 sensors location on frame6 11 troubleshooing6 10 types2 19 voltage levels2 19 x axis and y axis locations6 12 service connecting your machine to KVAL Service4 3 servo drives connections location6 24 location in main electrical panel2 17 servo positions feedback2 26 setup hinges group location2 33 setup screens2 31
60. fset FIGURE 3 5 Sample of an Adjustment Menu Note KVAL suggests to follow the steps in the order below Step 1 Verify and Adjust the Hinge Carriage Step 2 Verify and Adjust the Router Calibration Step 3 Verify and Adjust the Pre Drill Calibration 3 8 KVAL 994 X Operation Service Manual Check Specifications of the Front Section Step 1 Hinge Carriage Calibration Adjusting the X Axis h Run the Calibration Routine See Run the Calibration Routine on page 3 6 Use the H Block as a reference to determine the horizontal center of the calibration slot Figure 3 6 on page 3 10 shows an example of left and right off center locations 2 Measure the 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 n Locate the appropriate Menu in the Setup interface screens Combine with Base 6 If there is a number in the box under X Axis select the Combine with Base button to set a reference 7 Once this number is added to the base double select the box that has 0 000 A calcu lator will be displayed Enter the offset in this box 8 If it needs to go in the negative direction select the negative symbol 9 S
61. ge holder you are now ready to insert Start Sequence The start sequence drops the Six Shooter int e pocket while starting motor for hydraulic It also drops the screws down aided with air screws injection if equipped to speed the screw fee 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 zone Safety Insert Screw Slide Valve The insert screw slide valve provides the operator a remote air shut off to prevent the Six Shooter head from moving in when performing maintenance on the screw driver assembly It also is a good practice to shut slide valve OFF when not in use Screw Driver in close trap This allows the Six Shooter to hold the Apex bits in close to the screw receiver tubes This prevents the screws from bouncing out during the screw application It is also helpful when replacing bits or doing maintenance on 3 degree bevel front section Just plunge the head and flip the trap out of position This will allow the head to retract to the back position KVAL 994 X Operation Service Manual 2 9 Operator s Tour FIGURE 2 7 Identify Controls on the Six Shooter About the Hopper The Hopper sorts the screws for delivery to the screw gun The Hopper is attached to the Frame Interface which in turn 1s attached to the Six Shooter The Frame Interface allow the six shooter assembly to
62. gle auto Unclamping on or off The auto unclamp button sets the machine to automatically unclamp the door after machin ing is completed 2 30 KVAL 994 X Operation Service Manual About the Setup Screens About the Setup Screens Select the Setup Button on the Main Screen to open access to the e Main Cal Machine Calibration screen e Setup Hinge 1 4 screens e 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 shelf on the front section SB 2 EE O E Hi Ch To Hama Randy Lo start HOWE r quinca Ha DkTo Hama l uto Feed Waiting For Door fato Feed Modo HI Gk Te Home Ha Dk To Horma Machine Calibration y Lock Location nl uy Feed System Timing sn Diagn aa 0 590100 wm 2 500100 E Outfeed Stop mon gy aes Fi OO Fast Lock Plate Jamb Shelf Height 7 0 Timing me Vertical 3 5 aort 2 6250 _ Fa DONT Horizontal 4 lure 3 0000 a poo Oo Vertical Horizontal 3 00 Leck Routine Handy Lo Homa 6 9 infeed Stop 2 00 s LH Current Servo Position FIGURE2 15 Setup Menu KVAL 994 X Operation Service Manual 2 31 About the Setup Screens G Jamb Shelf Height Adjustment
63. h hinge location 2 14 KVAL 994 X Operation Service Manual Ud Operator s Tour Back Section e Works in partnership with front section process e Includes faceplate routing e Includes boring for lock and bolt Bolt Drill Valve Bank Controls Air Bolt Drill Motor Machines Extend and Cylinders on back section lock plate on the side of the Retract Cylin door der ae Ae on Bie ta ye a Lock Bore Motor and Drill Feed Belt Drills locks holes on the face o DGG Routs face plate arhe dor through Machine Face Plate Motor and Drill FIGURE2 10 Key Assemblies on the Back Section KVAL 994 X Operation Service Manual 2 15 Operator s Tour Out Feed e The door is automatically positioned to be fed into the next machine Servo Motor Con trols frame functions i MET En l i ie Syn i T Out eed Door is fed to A next stage Width is Valve Bank Con Opt O Air Blow off adjustable to Door trols frame functions Blows off dust from the door as it Feeds Out Main Machine Air Drop FIGURE2 11 Key Assemblies on the Out Feed Section 2 16 KVAL 994 X Operation Service Manual Ud Operator s Tour About the Electrical Panels The 994 X has a Main Electrical Panel and a High Frequency Panel Figure 2 12 below 1s an overview of the location of assemblies in the panels The Main Electrical Panel The High Fr
64. hed the door and jamb automatically is off feed as the next door enters the machine Hinge routing sections are completely servo controlled for pocket height width and depth Each hinge routing section is equipped with two 1 1 2 HP High Frequency spindle motors one for rout ing and one for pre drilling on both the door and jamb Servo motors allow the hinge router to accelerate out of and decelerate into hinge corners eliminating over travel Changeover from 3 1 2 to 4 hinges is accomplished by selecting the desired size on the touch screen Our Point to Point Pre Drill system can be programmed 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 productivity including hinge mounting is typically 35 55 sec onds However this varies depending on the operator and material flow The lock machining assembly will be positioned with a single servo driven ball screw This is controlled by the touch screen and will allow settings for standard lock and dead bolt locations based on the lock bore location A third dead bolt bore may easily be added by entering the posi tion on the touch screen The servo d
65. ical stops Incremental Incremental motion control is used when the load 1s required to be moved with high accuracy to multiple locations sometimes in multiple directions axes A typical KVAL usage for this system is a computer controlled router in a door light machine where there is great variety in the cut size shape and location Basic Control Circuit This section describes a basic control circuit The Figure below shows a block diagram of a com mon control circuit There are four parts to a motion control system 6 2 KVAL 994 X Operation Service Manual Ud About Motion Control A Position Feedback a Optional Positioning Instructions y Optional User Interface Controller Positioning Load Ss SS Translated System A Positioning Instructions Process Complete OK to move Machine s Other Subsystems FIGURE 6 10 Block Diagram of Basic Motion Control The User Interface A e Allows communication between the humans and the machine Examples A touch screen a PC or a button panel The Controller e Translates entered information into a form the positioning system can understand e Listens to the machine s other subsystems waiting for the OK to move command e Sends the positioning instructions to the positioning system e Listens to the positioning system for position status if there 1s a feedback loop e
66. identified in the figure below RJ43 to Intranet About the 994 X Computer The 994 X uses a Beckhoff CPU module as a PLC Programmable Logic Controller In addi tion to the CPU and the chipset the module also contains internal main memory The computer has a removable Compact Flash card from which 1t boots The controller uses a Windows A oper ating system with TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include e A smart power supply to connect to EtherCat terminals This supply contains a LCD to display system and user messages e A DVI USB module to connect to the user interface e An Ethernet module to connect to the servo amplifiers Connections on the PLC The CPU module is located in the upper left corner of the Electrical Panel See About the Electri cal Panels on page 2 17 The figure below shows an example of a common PLC Refer th the electrical drawing for detailed information Smart Power Supply CPU Module and EtherCat Interface to Servos RJ45 to Intranet 2 pe A gt l E pe Lem ia DVI USB Module Compact Battery Interface to to User Interface Flash Card Frame 4 2 KVAL 994 X Operation Service Manual UD System IT Administration FIGURE4 1 Connections on the Controller Backing up the Computer Backups keep your data archived in case of a rare system crash Click the Back Up Icon on the Desktop to b
67. iged GOOD AAA RN PA Codie flis hanaga KG sde Flebdanagos initliped F010 rihi A 00 tte Nall Catch Pork Cylindes ROCpliadar ladilla GUIDE AA SO ties Nall Catch Paidan Cylinder KDCpUndes Initiged 014 07 AP 5600 palaa Ball Cam Mesas KMar ameni Inilired 001403 1300 500 Paleo Hall Cai Plesgs Cylinded HCylindes Initiped DONAHA HAN 506 Poland Hall Catch Vertical Cylindes KDC ylindet Initiiged GO 03 1109795 560 feted Hall Catch Meter KMetarlontact initiired 01 00 A 50 fefeed Hall Catch Piumge Cylinda Cylinda initiyed 20101 01 0 61450 fasad Dall Catch Werra Cylinder KOC plinde Initlized AU AAA Pet Catch fall Catch Manager lei red AA 0979 26 SO Bach acia Cynder LOC Aldo initired Total Door Count 7014 02 FG 560 Sell Centering Clamp EC pisar sf cad 601403 09 96 500 Beh Dil Cylinda ROplindas ilire 014 0715 09 79 546 5606 Seh Dil Mets Eto Cera nel rel 0 O ap 10205954 SGi Funci nn Dill Clica EC pidas baiiia 0148 01 149 50 A ach jara Olinda Cylinder Initiiged 01 07 1079 500 lack lero Medes KMesarC oniact Initliped n AO M achro Ancla ini Leche ped ODE A fensa Pias Wiii Aip Ciplinder RC lindes Iniilzed 201401 0144 M0 Tap Plate Width Adjuni Cylinder EDO Under hhii ed Daily Door Sours 0 0 500 fl eck Plate Vertical Cylinder ECplador inlilizad SOMA SA Bock Plane irreal Cylinder MCylinder Initiaed F M OLEA Lech Plata THN Cynder MCylinder initiined 014 00 79 56 5600 ack Plate enter WTO AMeseWFD Initial
68. ins a touch screen that allows communication between the operator and the machine Through automation the station interface replaces manual setup thereby saving time Door cutting parameters can be stored and retrieved by one touch The Touch Screen logic also includes management functions such as Daily and Lifetime Totals See Description of User Interface Screens on page 2 25 and Quick Start on page 2 20 for more information Touch Screen Interface Controls e Emergency Stop e Start boot up and Stop e Lock Out ability to change pro grams e Turn ON or OFF Control Transformer FIGURE2 3 Operators Station with touch Screen Interface Machine Control The machine control is located is centrally located for easy access The control works with the Operator Interface to process a door The controls are listed in the illustration below See Quick Start on page 2 20 for more information on using this control in machining a door Start Sequence Starts the sequence of machining a door Emergency Stop If Safety issues occur press this button a ra LH RH Door Disable Auto Feed Feed Mode Select a Right Stops Door Feeding Chose Auto Hand or Left Through OFF or instant Hand Door feed thru FIGURE2 4 KVAL 994 X Operation Service Manual 2 5 Operator s Tour UMD Narrow Door Support Option V This option supports doors under 16 and allows machining on either lock or
69. ises the Six Shooter and feeds a set of six screws for the attachment of the next hinge The Six Shooter which is supported on ball bearing equipped steel wheels and is mounted on an overhead track The track and the Six Shooter are precisely aligned to ensure the hinge is properly position into the pocket at each hinge location Option Z Screw Changing Hopper for Six Shooter Screw changing hopper for changing screw colors 994 X Available Options Option R1 Push Button Quick Change 0 or 3 Degree Hinge Routing Price includes PLC logic and controls to allow front hinge routing section to rout on either a O degree or 3 degree angle Hinges will be flush mounted when installed on doors with either square edge or 3 degree bevel on hinge side Option O Door Blow Off System Air blow off tube cleans dust and chips from top of door Option V Narrow Door Center Wheel Support Supports doors under 16 and allows machining on either lock or hinge side with the use of a side shim This option has controls to set the width at 12 0 14 0 and 16 0 Shim is not included Option W Hinge Stops for 6 8 7 0 amp 8 0 Doors This option is limited to certain hinge pocket locations Consult with your KVAL sales representative Option SE Single Electrical Drop Price includes a disconnect mounted on one electrical box that will power both 994 X Electrical boxes Price includes wiring from the disconnect to each box About this Manual This manu
70. late when in Slow Vertical E1501 Plate mode ata 300 Horizontal The amount of time in seconds to give the horizontal movement of the lock plate when in Slow Plate mode 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 2 for head locations e Setup Hinge 1 e Setup Hinge 2 e Setup Hinge 3 e Setup Hinge 4 ea pen Lock sta Diesblad Power om Prent the GT ART button to comia t Pablo Plate Resat Plate Tilt eyt Disabled HH Chita ba arc pl os pa fit sable y a i 31 AEE E A i Current Servo Position FIGURE2 16 Hinge Setup Menu 1 of 3 KVAL 994 X Operation Service Manual 2 33 About the Setup Screens L Hinge Carriage Adjustments Hinge Carriage Hinge Carriage Location This calibration number adjusts the position of the hinge carriage in the X Y and Z direction TAE Edda 1 000000 Pre Drill Adjustments Pre Drill Pre Drill These adjustments move the point to point drill in the X Y and Z direction Router Adjustments Router Hija These adjustments move routers in the X Y and Z direction Ey denia This also adjusts the radius of the router cut l 500000 Use this to compensate for minor changes in tooling during cal f ET ibration a ae p 000000 De J aq r 2 34 KVAL 994 X Operation Service Manual
71. load Relay Light OFF 1 Check Motor Overload Circuits 2 With power on check the trip indicator LED on the overload If indicator is orange press the Reset Button to reset the overload circuit Retest the Machine Trip Indicator Contactors Factory Set Current OF Overload Rating Adjust 7 Relays se Reset Button Fac tory set on the H Setting z E Stop Light OFF Check to see the 1f 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 O Stop Light OFF Check for 110 VAC between 2 and 4 If there 1s voltage press the Start button If no voltage check the Stop button to make sure it is all the way out and not stuck in then check the contact to make sure it is closed If still no voltage check the wiring 6 18 KVAL 994 X Operation Service Manual Troubleshooting Electrical Problems Start Light OFF If the Start light remains unlit push in the Start button and hold it in while a second person checks for volt age between 2 and 75 If there is 110 VAC replace the ACR relay If there is no voltage while the button is held in check the wiring 24VDC Light OFF First isolate the power supply Check between DC and DC for 24VDC If no DC voltage disconnect the output V and V wires fr
72. lubricator to insure that 1t 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 e KVAL P N SYSLUBG e Chevron AW Hydraulic Oil 32 e G C lubricants light AW R amp O e Mobile DTE 24 e Shell Tellus32 e Gulf Harmony 32 To prime the lubricator find an air line on the carriage section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose Repeat this same procedure for the back section and other trouble areas It is recommended to check the lines every week to two weeks 5 6 KVAL 994 X Operation Service Manual Ud Lubrication Points on the 994 X Lubrication Points on the 994 X Feed System Use Lube EP2 or similar to Lubricate Chains Lubricate feed sys tem hex shaft with Silicon Spray FIGURES5 5 Feed System Lubrication Points KVAL 994 X Operation Service Manual 5 7 Replacing Bits Replacing Bits The 994 X is a powerful electro mechanical motion Caution control system If servicing the 994 X follow the safety guidelines described in Failure to do so can result in damage to equipment and or serious injury to personnel Replacing Bits in the Front Section This section describ
73. ma Boulevard South Petaluma CA 94952 e Phone and Fax In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 e Business hours Technical Support 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday Parts amp Service Sales 6 30 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday Other sales related inquiries http www kvalinc com e Email service kvalinc com KVAL 994 X Operation Service Manual KVAL 990 H Operation Manual Your Feedback is Welcome To help us design products that make your job easier and your business more successful we d like to gain your perspective about your user experience with our product that 1s the manual the machinery the software etc What was easy or difficult to use or to learn If you could change something about the design what would it be Please email your comments and suggestions for improve ment to userexperience kvalinc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information above Thank you http www kvalinc com KVAL 994 X Operation Service Manual KVAL 994 X Operation Service Manual Table of Contents Chapter 1 Introduction to the 994 X Door Hanging System Chapter ata Gancedo lt is 1 1
74. may cause a VFD to shut down The reset buttons are located on the door of the VFD panels The button contains the VFD func tion printed on the button If a VFD is tripped to OFF the button will be lit To reset a VFD 1 Push lighted button to reset the indicated motor a If the button light turns off continue with production b If the button stays lit find the source of the down motor printed on the but ton For example if the feed thru motor is not working at operator station turn the motor on and off to reset c If issue continues get the error code off the VED and look up the error code in the VFD manual Follow the instructions in the VFD manual If issues con tinue contact our Service Center See Getting Help from KVAL on page 1 13 VED Reset Buttons FIGURE 6 17 VFD Reset Buttons Note The number of reset buttons depends on the machine type and option The fig ure above shows a machine with 11 VFDs Note The VFD manuals are located in the Electrical Panels On some machines documentation can be found in the operation station in the documentation folder 6 20 KVAL 994 X Operation Service Manual Ud Troubleshooting the Air Cylinders Troubleshooting the Air Cylinders Most cylinders have an extend and retract port To adjust the extend motion of a cylinder you must adjust the flow control on the retract port this regulates the air flow exhausting from the cyl inder and th
75. mber If light is OFF go to item B on page 6 18 STEP 3 E Stop Amber If light is OFF go to item C on page 6 18 STEP 4 Stop Amber If light is OFF go to item D on page 6 18 STEP 5 Start Amber If light is OFF go to item E on page 6 19 STEP 6 24VDC Green light is OFF go to item F on page 6 19 6 16 KVAL 994 X Operation Service Manual Troubleshooting Electrical Problems A Control Power Light OFF 1 Check if the Control Transformer button is pulled out 2 Is the Disconnect Switch on the main electrical cabinet set to ON Switch 3 Is there 208 220 440 or 575 VAC to the top side input of the Control Trans former If not check the fuses at the Fuse Block and the contacts on the Control Transformer button on the switch panel Typical Control Transformer Input Output High Vac 110 Vac _ 4 Is there 110 VAC between 1 amp 2 on the 110 VAC Terminal Strip If not check the fuse on the output side of the Control Transformer If fuse 1s good check power coming out of Control Transformer 5 If no power on the output side and there is power going into the top of the Control Transformer replace the Control Transformer 6 If there is power at the Control Transformer check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip KVAL 994 X Operation Service Manual 6 17 Troubleshooting Electrical Problems Over
76. n 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 35 This section also contains the file list window which displays files that are available to use Back Section Group Set the lock parameters ack Enabl in the Back Section group ELA The settings include lock cae oh ore 000 Y specifications for 3 lock so settings the ability to Lock 3 l Ma eee 0 000 enable and disable lock LEE Location Sten _9 000 bore bolt drill and face plate routing Fast Plate can be enabled or disabled Lock Backset Option shows the backset for each head KVAL 994 X Operation Service Manual 2 29 Description of User Interface Screens Auto Enable and Disable Buttons From these buttons you can toggle auto functions on or off Auto Feed Option Press Auto Feed to toggle the auto feed on or off In auto mode the feed system will bring in and clamp a door wait for pro cessing to complete then feed the door to out Feed Through Option Press Feed Through to toggle the feed through Mus 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 tog
77. n 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 Repeat steps 1 3 for each Hinge 5 Return the Six Shooter to the park start ing position The machine will not run if this is not completed 6 When finished with Hinges unclamp the door and jamb by either pressing the Unclamp button on the Six Shooter or pressing the Jamb Clamp foot pedal Continue Machining To continue repeat from the load door section in this quick start Power Down If completed shut down the machine See How to Power Down the 994 X on page 2 23 KVAL 994 X Operation Service Manual 2 21 Powering Operations for the 994 X Powering Operations for the 994 X This section describes how to power up and to power down the 994 X Powering up the system includes e Applying power to the entire system e Starting the Control Circuit Powering down the system includes e Shutting down the control power e Removing power from the entire system How to Power Up the 994 X 1 Ensure factory air is applied to machine and main air supply is turned on 2 Check that all E Stop buttons are out and safety gate door s are closed Note A pop up is displayed on the user screen if an E Stop is pressed The pop up will indicate which E Stop has been activated 3 Make sure the electrical disconnect the electrical cabinet
78. nder high pressure and can be very dangerous when activated Before performing any mainte nance or repairs on this machine turn off the main air disconnect Lockout and tagout this connection See Lockout Tagout Procedure on page 1 8 KVAL 994 X Operation Service Manual 1 5 Safety First Electrical Electrical circuitry on this machine is protected by an Still has power approved lockable disconnect ee DOr lon circuit In addition to this equip ment you must install an approved disconnect for the electrical power supplying this machine When opening the cabinet you must first turn off the disconnect switch When the cabinet door is open there is still power on the top side of the disconnect switch Some machines are powered by more than one supply located at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Before Conducting Maintenance Prior to performing any maintenance repairs cleaning or when clearing jammed debris you p ANG FR must disconnect tag out or lock out the elec trical and air pressure systems This should be HO USE LOCKOUT done in accordance with applicable state and Cas BEFORE WORKING or federal code requirements Xes ON EQUIPMENT 1 6 KVAL 994 X Operation Service Manual
79. ock Plate Timing oooooonnnnnnnnnnnnnnnonocnnnnnnnononnnnnonnnnss 3 1 About Calibration About Calibration Calibration is all about the confidence in the end results of your manufacturing process Calibra tion assures you that your cut parameters are accurate and within the specified limits In troubleshooting calibration can be an essential step in solving the issue The goal 1s to start with a known reference to confirm and isolate issues that can cause improper cuts The KVAL 994 X has a built in Calibration routine to cut a horizontal slot with known parame ters The routine allows you to make the cut measure observe any anomalies and help isolate to the component that causes the problem This chapter describes how to use the Calibration routine Before you Calibrate 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 did the problem first start during a run at start up 4 When was the last calibration 5 Is the door square straight and bevel correct 6 Ensure the door is tight against all H Blocks 7 Ensure the door is clamped up tight against the reveal 8 Is the router or pre drill depth correct Use a Router Bit Depth Gauge PN 432C to check depth 9 Check tools for wear 10 Check back side of th H Blocks for sawdust build up
80. om the 24VDC power supply and check for DC voltage where those wires were disconnected If no voltage Check the input side for 110 VAC If no 110 VAC check the fuse If there is 110 VAC and no 24VDC replace the 24VDC Power Supply Input 110 VAC Output 24 VDC If there is 24VDC Reconnect the output wires to the 24VDC power supply Trace the output wire to the DC terminal block Disconnect all 24V positive wires from the DC from the DC terminal block except the output wire from the 24VDC power supply Check for 24VDC at between any DC and DC terminal on the DC Terminal block Reinstall the 24V positive wires one by one checking for 24VDC after installing each If at any point no voltage is found trace the last reinstalled wire and check for shorts KVAL 994 X Operation Service Manual 6 19 Troubleshooting Electrical Problems About VFD Troubleshooting This section describes some troubleshooting tools for the VFDs Error Checking on the Variable Frequency Drives VFDs Variable Frequency Drives interact with hinge and faceplate routers width adjust motors and feed motors If issues occur error codes are displayed on the VFDs To help troubleshoot refer to the VFD manuals located in the High Frequency Panel for lists of the error codes See About the Electrical Panels on page 2 13 for loca tions of VFDs Using the Reset Buttons In some rare occasions an electrical spike
81. or Tripped Circuits 1 Remove lock and tag outs on the main power sources 2 Manually close disconnect sensors and energize the control circuit or transformer with its respective sensor Check the Status Light Panel If all lights are observed there are no overloads or emergency stops tripped See Troubleshooting with the Status Light Panel below for more information Note Most electrical problems are related to mechanical malfunction e g stuck motors jammed chain blocked photo sensors etc Note If a solenoid valve is suspected and not cleared in the air checks section see it can be electrically jumped to check operation Troubleshooting with the Status Light Panel The Status Light Panel is located on the Electrical Panel All six lights are illuminated when the system is in proper working order The lights turn on in a sequence and will stop at the point where a fault is first detected KVAL 994 X Operation Service Manual 6 15 Troubleshooting Electrical Problems The sequence that the lights turn on are as follows 1 Control Power Amber 2 Overload Relay Amber 3 E Stop Amber 4 Stop Amber 5 Start Amber 6 24VDC Green If one or more lights are OFF follow the process below to isolate the cause NOTE Be sure to proceed down the table starting with the CONTROL POWER light STEP 1 Control Power Amber If light is OFF go to item A on page 6 17 STEP 2 Overload Relay A
82. or a new cylinder c If the valve is not receiving an electrical signal for instructions It might be necessary to call in a specialist or check with KVAL customer service at 1 800 553 5825 5 If an Air Leak is coming from an exhaust port on the solenoid air bank a Check the solenoid for the manual override If the solenoid has a manual over ride you can push each of the buttons one at a time When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty Adjusting Cylinder Extension Speed Air Supply Out Air Supply In Coe Ts le el Acer Tere Lo Pol Adjust i aClory a i p 4 niy im flew Gori Counter clockwise to speed up cylinder movement y y e gt j F J j L BIMBA A Adjusting Cylinder Retraction Speed Air Supply Im Air Supply Cut Do Not adjust Factory Set Clockwise to slow cylinder movement Ai Supply ln tow control Counter clockwise to speed up cylinder movement E El a See BIMBA l ska msn 6 22 KVAL 994 X Operation Service Manual Network System Overview Network System Overview A PLC controls the 994 X The 994 X PLC can process multiple analog and digital inputs and output arrangements The system can handle extended temperature ranges immunity to electrical noise and resistance to vibration and impact Figure 6 18 below shows the
83. ot avoided it will cause death or serious injury e WARNING means if the warning is not heeded it can cause death or serious injury e CAUTION means if the precaution is not taken it may cause minor or moderate injury Safety Guidelines In addition to the caution and warning labels affixed to this machine follow the guidelines below to help ensure the safety of equipment and personnel Training Ensure that all employees who operate this machine are aware of and adhere to all safety precautions posted on the machine and are trained to operate this machine in a safe manner 1 4 KVAL 994 X Operation Service Manual Safety First Car When the Machine is O Compressed Air Never operate the machine without proper eye and protection N e Never reach hands beyond safety cage Servo motors can unexpectedly move quickly e Never clear screws or hinges out of the machine while it is running e Never reach into the router area to retrieve a hinge The router may still be running down after shut down e Never perform any maintenance unless machine is at zero state e Never clean the machine while it is running e Never walk away from the machine while it is running The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief To avoid possible injury lockout pneumatic power before servicing All cylinders on machine are u
84. pecifications as a reference you can inspect the pattern and the specifications of the slot for inaccuracies The front end assemblies that use the calibration routine are as follows 1 Hinge Carriage 2 Router 3 Pre Drill Router Pre Drill Hinge Carriage FIGURE 3 2 Location of Assemblies 3 4 KVAL 994 X Operation Service Manual HA r ni SAL About the KVAL Calibration Routine Calibration Slot Drilling Specifications The calibration routine will route the following slot with the dimensions and positioning below Slot Position Center of Door Edge Center Between H Block Pilot Hole Position Center of Slot Width Diameter of Drill Router Slot Depth 0 250 Length 1 000 Diameter of the Router Width Diameter of Router Depth The Hinge Depth Setting from the Operators Station KVAL 994 X Operation Service Manual 3 5 Run the Calibration Routine Run the Calibration Routine After checking for common errors start the calibration cut process Select Calibration From the Main Screen choose Calibration nable Calibration from the Menu list on the Hinge Spec Group 100 NOTE If Calibration is not on the list con Length 3 6000 tact KVAL service KVAL service can 80 rng Bev Hinge BackS lt 0 2500 remotely download the program if LAN and WEB enabled e im 0 0970 aclelllim 06250 FIGURE 3 3 Calibration Routine Selec
85. r Inside Narrow Door Outside Option Option Inside of Fence Before In Feed Stop Outside Of After In Feed renee Stop Valve Bank 1 Q Designators Door In Machine Valve Bank 2 Q Designators Valve Bank 3 Q Designators Width Adjust ment Sensors Before Out FeedStopEye After Out Feed Stop Eye FIGURE 6 14 Location of Sensors Top View 994 X KVAL 994 X Operation Service Manual 6 11 Location of Sensors on 994 X UMD Z Axis and Y Axis Front Section Sensors Figure 6 15 below shows the placement of the Z Axis sensors and the Y Axis sensors The Y Axis sensors 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 Z Axis Home Eye Z Axis Reverse Crash Eye Z Axis Forward Crash Eye Y Axis Home Eye Y Axis Reverse Crash Eye Y Axis Forward Crash Eye FIGURE 6 15 Figure 6 15 Section View of 994 X Y and Axis Sensors 6 12 KVAL 994 X Operation Service Manual Location of Sensors on 994 X X Axis Sensors Front Section Figure 6 16 below shows 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 Reverse Crash Eye X Axis Forward Crash Eye m A AP 1 oer
86. re Windows is shutdown completely before turning off the machine Hard drive or data may be damaged if not turned off in this order 2 Switch the green CONTROL TRANSFORMER switch to the OFF position 3 KVAL also recommends that you turn the disconnect switch on the electrical cabinet to OFF this helps reduce possible damage resulting from power surges from electri cal storms KVAL 994 X Operation Service Manual 2 23 Powering Operations for the 994 X AL Emergency Shutdown and Recovery There are emergency shutdown E Stop switches located at key points around the machine Note Depending on options of the machine the E Stop buttons 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 1s killed The machine responds in the same way 1f you press the STOP button on the operator s station 2 24 KVAL 994 X Operation Service Manual Description of User Interface Screens Description of User Interface Screens This section describes the user interface screens The user interface allows the operator to use a touch screen to control the door cutting process auto run manually run the door store door pro files and use diagnostics to help troubleshoot the 994 X Screen Selection Menu Map Below are the menu selections for the 994
87. rive Control An adjustable speed drive 1s used to control the motor speed and torque by varying motor input frequency and voltage A variable frequency drive VFD is used in KVAL machinery The figure below shows a block diagram of a typical motor drive circuit with typical voltages Common Motor Drive Control Line Voltage Power Should measure Should measure Control Voltage lt lt Line Voltage here 24 VDC here Fuse s Should measure PLC Line Voltage here Output ON 0 STF Forward Power Run OFF STR Revers 2 Input 300 lt lt l 0 Motor Run Light Drive should be ON OFF RL Power SD COMMON Output Should display the Motor Frequency Control Circuit lt 7 Motor Common ON FIGURE 6 12 Block Diagram of a Common Drive Control KVAL 994 X Operation Service Manual 6 5 About Motion Control Typical Positioning System Pneumatic Circuit A control valve solenoid is used to drive cylinders to move different loads in the machine For Example extending and retracting router drill clamping a door Should measure Control Voltage High Pressure 24 VDC here Air Should have High Pressure air here PLC Output A t npu ON ASA Control Control Coil Valve Input Air Output a Should have High Control Circuit Pressure air here Common Cylinder Extended FIGURE 6
88. riven system will automatically position the lock boring assembly when the door hand is changed Lock detailing includes 2 1 8 face boring with push button change over between 2 3 8 and 2 3 4 back sets 1 bolt drill and face plate routing Face plate routing will be accomplished with a 1 1 2 hp Hi Frequency spindle motor The 994 X will accommodate doors with raised molding one or both sides up to 3 4 high and a minimum of 4 between the raised molding and the edge of the door This machine is equipped with a solid state touch screen that replaces many of the mechanical switches for the machine functions The touch screen also includes the capability to view the sta tus of the various photo eyes and switches for quick diagnosis when needed without having to open the electrical panel or for the operator to leave his work station The Touch Screen logic also includes management functions such as Daily and Lifetime Totals 1 2 KVAL 994 X Operation Service Manual UD Overview of the 994 X Door Hanging System About the Six Shooter The 6 Six Shooter screw gun will attach 3 1 2 X 3 1 2 hinges to the door and jamb 9 X 3 4 long flat head screws are automatically sorted and fed six at a time to the screw gun The opera tor manually places the hinge onto the magnetic indexing fixture and then rolls and pivots the Six Shooter into an H block at each hinge location to attach the hinges Pressing the Reset switch then ra
89. s 5 5 Bal SCrOWS Pe o O a 5 5 DeSCription Of Air INPUT Oya 5 5 Adjusting the Air Line Lubricator ccessseccssseeseseeceaseesenseeoesseeseseesonsees 5 6 Priming the Air Line Lubricator scccesseceeesecsesssccssseceseseeessecenseeoesesees 5 6 Lubrication Points ON the 994 X ssssssannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 5 7 FEO Mi 5 7 FRCDIAGING BIS CP Pee CP a aa EEE 5 8 Replacing Bits in the Front Section ssccssssseecssseeecesseescesseesonseessonseesees 5 8 How to Access to Bit Assemblies ccccocccccccnnonanonaconanconancnnnaronaronanannanannnans 5 9 Remove and Replace the Screwdriver Bits ccsssseccsseesesseeseeseseenees 5 11 BaCk OC ClO ai aieea 5 12 Changing the Bore DVillssssecasseudcassarsasautecessesqowacvsnussasesecuiesedaskercwsssineecs 5 13 Ghandna the Bot Drees aiina ana a eaaa 5 13 Changing the Face Plate Router scccsssseccsssseecssseeseesseesenseessenseesees 5 14 Chapter6 Troubleshooting the 994 X About MOON CONTO las dis 6 2 Basic Control Gillian iia 6 2 Typical Positioning SY SIS INS siii didnt 6 4 THOUDIESNOOTING BASICS cceasnctsacasiectsccieveccanadecssesdscacseernesaaceczze 6 7 Belore VOLPAQIUS aii deis 6 7 AnialyZe the SUD SYSICINS mssnrconi nndo da cidcid 6 8 Using Sensors to Trouble SNOOt csececceseeeeeeeeeeeeeeeeeeeeseeeneeseees 6 10 Location of Sensors ON 994 X vv wssscssscssensecnsecnnenseenseenescenensenneses 6 11 KVAL 994 X Operation Service Manual Z Axis an
90. s Jamb Shelf Height Adjusts the jamb shelf height This parameter is usually Semin 26250 Set once Mates 2 6250 Lock Location Adjustments Lock Location Maca i EZS Adjusts the lock location in the back section Adjustments can be made for right hand and left hand doors for 6 8 7 0 and 8 0 door SIZES Lock Location Choose the desired size door 6 8 7 0 8 0 or Base Base Moves the lock location for both left hand and right hand doors This is the original reference LH Moves the lock location for left hand doors only RH Moves the lock location for right hand doors only Feed System Timing Feed System Timing Adjustments Infeed Stop This is distance the clamped door is located Infeed Stop Y after the after infeed eye did ae Out feed Stop This is the distance the clamped dooris Hd 2 00 in located after the before out feed eye Fast Lock Plate Timing Fast Lock Plate Timing Vertical The amount of time in seconds to give Vertical the vertical movement of the lock plate when in Horizontal Fast Plate mode the horizontal movement of the lock plate when in Fast Plate mode Horizontal The amount of time in seconds to give 2 32 KVAL 994 X Operation Service Manual About the Setup Screens Slow Lock Plate Timing Q Slow Lock Plate Timing Vertical The amount of time in seconds to give the panenn vertical movement of the lock p
91. s may be made in the off position The key may be taken out in the off position to prevent any inadvertent changes to the cut parameters Set Up Lock 2 26 KVAL 994 X Operation Service Manual Ud Description of User Interface Screens Main Screen The Main Screen is also the startup screen for the 994 X From this screen all the basic user inter face controls are available to run a door HAL Ok To Horne Randy to start HOME GUNG Ha Oh Teoria Lack modta Randy to Heme lAuto Feed Viatliieg For Door Auto Feed Moda HI Ok To Home HA Ok To Homa Length Hi Hinge BackSet nae i e ers ETE 06260 Mo Pra Drill Pattern Lock 1 Beefy Lock 2 oo Lock 3 i kot tani 0 000 Location Shift bt H amp FIGURE2 14 Main Screen KVAL 994 X Operation Service Manual 2 27 Description of User Interface Screens AL Home Machine Button This button starts the home sequence on the machine which slowly scans to find a physical reference point Stop on the frame When this point is found the position is Door Home stored and then used to calculate the location of all Machine Sequence moves after this The home sequence must be performed every time the machine is powered up or reset Reset Machine Button If a fault occurs that cannot be cleared press the Reset Machine button This button will reset the machine to the start position before homing
92. sembly is the workhorse of the Six Shooter The assembly automatically receives aligns and drives the screws into the door and the jamb 2 12 KVAL 994 X Operation Service Manual Operator s Tour Gearbox Chucks X6 Hydraulic Motor Geared to drive 6 Holds 6 screws screws simultane aligned to the Door ously and the Jamb Hinge Applicator Location to attach Hinge Turret to Adjust Depth Adjustable stops to set l Forward Stop the depth of the screw Fa dan Limit Switch drivers Used with the oves Ine Screw x _ Forward Limit Switch i Reverse Stop Limit on drivers into place aar ie Magnets Four Magnets hold Hinge Screw Receiver Tubes for Application These tubes receive the screws from the hopper by way of plastic tubes Split Shells X6 Receives 6 screws straight ens and aligns them j Hinge Indexer X2 actory set to align Index Spacers X2 hinge Factory set to align hinge Latch Arm atches to H Block Latch Arm Cylinder to secure in place Moves latch arm in and out of position FIGURE2 9 Six Shooter and Gear Box Call Outs KVAL 994 X Operation Service Manual 2 13 Operator s Tour UD About the Overhead Track The Six Shooter which is supported on ball bearing equipped 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 eac
93. sources multiple electrical sup plies air supply and pressure spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shut down 3 Obtain locks keys and tags from your employer s lockout center 4 Disconnect power a Turn the disconnect switches on the main electrical panel to the OFF position Then pull out the red tab and place a padlock through the hole Place your tag on the padlock as per the tagout guidelines below see illustration below When multiple people are working on the machine each person needs to have a lock on the handle in the extra holes provided EEE b Turn the disconnect switch on the larger high frequency panel to the OFF position Then pull out the red tab and place a padlock through the hole Place your tag on the padlock as per the tagout guidelines below 1 8 KVAL 994 X Operation Service Manual Safety First 5 Turn the main air valve to the OFF position and place a padlock through the hole see 1llustration below NOTE Place your tag on the padlock as per the tagout guidelines below 6 Once the locks and tags are in place and all personnel are clear attempt to operate the machine to ensure equipment will not operate 7 Maintenance or repairs may now be completed The person performing the work must ensure all tools spare parts test equipment etc are completely removed and that all guards
94. spective circuits PLC controllers also have lights on them for the input and output functions You can easily find out which circuits are failing by watching the lights turn on or off Compare the lights on the IDEC or Beckhoff controllers to the electrical print to determine what systems are being affected If the Power Stops During Normal Operation 1 Check that the input power disconnect switch is not turned off 2 Check that all of the emergency stop buttons are in the normal position 3 Check the Six Lights on the Electrical Panel See Troubleshooting with the Status Light Panel on page 6 15 Lockout and Tagout the main power source 1 Turn the panel disconnect switch in the off position open the electrical panel door 2 Observe the disconnect switches Look for loose or broken wires at the disconnect then at all of the components 3 Check for continuity of all fuses with an OHM meter Fuses need to be removed from the bottom side of the fuse holder before measuring the fuses 6 14 KVAL 994 X Operation Service Manual Troubleshooting Electrical Problems 4 With the power off check for motor overloads by pressing each reset button usu ally at the bottom of the panel in SEQUENCE If one is tripped there will be a slight resistance to touch and a click sound as it is reset l ____ __ _ ____ Press Reset TTO sees Trip Indicator Test Thermal Overload Relay Check f
95. stem description5 5 lubricator5 5 air line lubricator adjusting5 6 priming5 6 air line lubricator maintenance schedule5 2 air valve lockout tagout1 9 auto enable disable buttons description2 30 B back section checking specs3 14 key assemblies2 15 menu path to calibration3 14 back section group description2 29 back section status feedback2 26 ball screw maintenance schedule5 2 base readout description3 8 Beckhoff CPU module4 2 bit assemblies how to access5 9 bits replacing5 8 C calibration description3 2 drill3 5 KVAL 994 X Operation Service Manual flowchart3 3 front section assemblies3 4 lock location3 15 path to hinge setup3 8 pre drill3 12 router slot dimensions3 5 router steps to3 11 slot dimensions3 5 steps before3 2 suggested order of steps3 8 chisels replacing5 8 collet assembly inspection5 9 5 13 combine with base how to use3 8 computer as a PLC4 2 backing up4 2 4 3 control panel light not on troubleshoot6 17 control power indicator light description2 18 control transformer switch power up2 22 2 23 D diagnostic screen description2 39 door spec group description2 29 drill bit replacing5 8 dura lith grease bearing lube5 2 DVI USB module location4 2 E electrical panels description2 17 emergency shutdown description2 24 e stop light description2 18 EtherCat smart power supply4 2 terminals location4 2 ethernet module connection to servo amplifiers4 2 F fe
96. t Door Additional Functions Currom Servo Position i Hs FIGURE2 18 Manual Operation Screen Jeg Hinge Camisge 1 Joy Hinge Carriage 2 Jeg Hinges Camiags F Joy Hinge Carriage 4 A Aart Hinge Servo Jog FIGURE2 19 Jog Carriage screen 2 36 KVAL 994 X Operation Service Manual Ud About Manual Operation Width Adjust Operation Width Adjust e Open Press and hold the Open button to open the width adjust carriage To stop the carriage release the button The carriage will also stop 1f the positive travel limit eye is activated e Close Press and hold the Close button to close the width adjust carriage To stop the carriage release the button The carriage will also stop 1f the negative travel limit eye 1s activated Door e Stop Press the Stop button to extend or retract the appropriate door stop e Clamp Press Clamp to activate the cylinders that clamp the door Feed e Reverse Press and hold the Reverse button reverse the feed of the door To stop the feed release the button e Forward Press and hold the Forward button to move the door feed forward To stop the feed release the button e 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
97. tart on page 2 20 If machining both sides of the doors flip the doors over to machine the other edge the doors Ensure the doors are side by side as close to the original setup Re perform steps 1 through 9 2 6 KVAL 994 X Operation Service Manual Ud Operator s Tour Hinge Carriage There are 4 Hinge Carriages on the front section Each carriage includes e A router to automatically rout a hinge pocket on the door and jamb e A pre drill to drill pilot holes in the hinge pockets to ready the insertion of screws by the six shooter Pre Drill Router Routs the Drills pilot holes hinge pocket on the for insertion of jamb and the door screws on the at the same time as jamb and the door the counter rotate router FIGURE2 5 Hinge Carriage Parts About the Six Shooter System The Six Shooter system simultaneously drives six screws into the jamb and the door to attach the hinges This section describes the assemblies of the Six Shooter Below is a general description of how to use the Six Shooter 1 Screws are poured into the Hopper at the top of the machine where they are auto matically sorted 2 Six screws are air injected though tubes to the screw gun at the bottom of the six shooter KVAL 994 X Operation Service Manual 2 7 Operator s Tour mM 3 The Six Shooter is mounted on an overhead track that 1s precisely aligned to ensure the hinge is properly position into the pocket at
98. tector circuit and a solid state output The ferrite core and oscillator create a field generating out the front of the sensor When a metal object enters the field a loss in amplitude occurs The detector circuit recognizes the loss of ampli tude and generates 0VDC to send to the PLC When the metal object leaves the sens ing area the sensor to returns to 24VDC and sends it to the PLC e As a result if a metal object is sensed the output of the sensor equals OVDC Refer to Figure 2 13 on page 19 for some examples of Sensors Photo Eye Detector Proximity Detector Emitter and Receiver Senses metallic in one package objects FIGURE2 13 Examples of Sensor KVAL 994 X Operation Service Manual 2 19 Quick Start C Quick Start Power Up amp Home Use Main Screen Load Door Load Jamb Ensure factory air is present at the machine and the 994 X main air supply valve is turned on Power up the 994 X See How to Power Up the 994 X on page 2 22 Home the 994 X See Home the 994 X on page 2 23 From the Main Screen choose a Preset button to load door parameters or choose your own setup through the Main Screen selections See Main Screen on page 2 27 From the control bar on the middle 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 Left Hand r Auto Feed Start Right Hand ON
99. the Back Section Calibration of the Back Section For the 994 X there are two screens available to calibrate the back section From the Main Screen select Setup gt Main Cal to get to the Machine Calibration screen to access e Lock Location Calibration e Lock Bore Location From the Main Screen select Setup gt Lock Plate Setup to get to the Lock Plate Setup screen to access e Lock Carriage e Router L Manual Diagnostics Setup Hinge 2 Setup Hinge l 3 Setup Hinge 4 Pre Drill Setup FIGURE 3 10 Path to Calibration screen Back Section 3 14 KVAL 994 X Operation Service Manual AL Calibration of the 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 location 1s correct there 1s no need to perform this process If it is not correct follow the instructions in See Adjusting Lock Location below FIGURE 3 11 Reference Door Lock Adjusting Lock Location Lock Location ona 1 Select the size door 6 8 7 0 8 0 or Base b 100000 2 Select Right Hand or Left Hand depending on the door 6 9 run through process Es 1000000 Ey Under Base select the Combine with Base button 4 Enter a
100. tion 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 Disable three of the hinges leaving one hinge enabled Load the Door and Start the Cut 1 Load the test door into the in feed of the 994 X 2 Verify the setup and check for machine is safe to run 3 Press the Start button to begin the process 3 6 KVAL 994 X Operation Service Manual Ud Run the Calibration Routine About Motion of Servo Motors X Y Z and W The figure below shows the motion of the X axis Y axis Z axis and W axis Use the figure below as a reference when calibrating the machine The reverse direction equates to a negative number and the forward direction equates to a positive number when entering data into the cali bration menus Use this information as a guide to help input the directional data in the calibration routines W Servo Motor X Servo Motor Z Servo Motor Y Servo Motor Red Close Red Reverse Red Up Red Close Green Open Green Forward Green Down Green Open width adjust Z Axis W Axis Y Axis X Axis Red Reverse Direction Green Forward Direction KVAL 994 X Operation Service Manual 3 7 Check Specifications of the Front Section Check Specifications of the Front Section Follow these steps in this section to verify the result of the cut and 1f necessary adjust the ma
101. u a 1 3 Sdlety Guidelmes rn ie Rabo renee tesa 1 3 Lockout Ticout Procedir aio l 7 Follow the P R O P E R lockout rule of thumb oooonnnnnnncnnnnnnnncnnnnnnnnnos 1 9 o as O A a Sarwan obit E nears atv ee manencns 1 10 Zero Energy State to Start Up to Operating State coooooooonncncnnnncnnnnnanonnnnss 1 10 Gettine Help Ton Kval is 1 12 Om LEme Help au A it 1 12 ProduetiRetura Procede rc das 1 12 Satety SNOR SDC tidad ais 1 14 A Note TONG OPeratOl ana a 1 14 1 1 Overview of the 994 X Door Hanging System Overview of the 994 X Door Hanging System KVAL s 994 X offers a high speed pre hanging line with the additional flexibility of servo con trolled hinge routing sections This includes high frequency spindles and programmable point to point pre drilling The 994 X is designed for both interior exterior doors and jambs It will accommodate 1 3 8 and 1 3 4 thick doors with a minimum width of 18 and a maximum width of 42 Door lengths of 6 8 or 8 0 can both be machined Hinge locations automatically shift between two pre determined factory set locations to accommodate both three hinge pockets 6 8 and four hinge pockets 8 Changeover does however require manual repositioning of the jamb clamp fixtures but can easily be accomplished in under two minutes without the use of tools The door is power fed into the machine and clamped into position After the hinges are attached and machining is finis
102. uirements ooooonnnnnnncnnnnnnnocnnnnnnnnnnnononaninaninnnnnnos 5 5 BAUS ONE mia 5 5 Description Ol Air Input System A oot ude ees 5 5 Adjusting the Air Line Lubricator ooonnnnncccnnnccnnnnnncnnnncnnnononananonannnononnnnnss 5 6 Priming the Air Line Lubricator ooooccnnnccnnnnnccnnonncnnnccnnnononanocnnnncnnnnnnnnss 5 6 Lubrication Points onthe 994X ii 5 7 Peed Syek non oc ici dadas 5 7 Replace BIS ars sto 5 8 Replacing Bits in the Front Section oooooonncnnnnccnnnnnnonnnnnnnnnnnonnnnnanoncnnnnnnnnnnons 5 8 How to Access to Bit Assemblies ii eee 5 9 Remove and Replace the Screwdriver Bits oooooonnnnnnnncncncnnnnnoncnnnnnnnnnos 5 11 Back Section amis illa 5 12 Chanoine the Bore Droll ra 5 13 Chansme the Bot DIE epi sets copa a od 5 13 Chaneie the Face Plate Router il 5 14 5 1 Maintenance Schedule UD Maintenance Schedule KVAL recommends the following maintenance schedule to ensure that the machine operates properly Refer to this section for steps to perform maintenance TABLE 5 1 Recommended Lubrication Schedule Type of Assembly Recommended Schedule Recommended Lubrication Type Pillow Block Bearing Every 250 Hours of Machine Operation Dura Lith Grease KVAL P N Lube EP 2 Flange Block Bearing Air Line Lubricator One drop of oil every 2 or 3 cycles Either lubricant listed below is approved to Check the lines every week to two weeks KVAL P N SYSLUBG Chevron AW Hydra
103. ulic Oil 32 G C lubricants light AW R amp O Mobile DTE 24 Shell Tellus32 Gulf Harmony 32 Gear Box 2000 Hours of Machine Operation or six months AGMA 8 gear lube of operation MOBILUBE HD 80 W 90 or equivalent Daily e Blow off dust from the entire machine Wipe down the outside of the machine with a clean dry cloth e Check tooling for wear e Wipe off the photo eyes with a clean dry cloth and check to ensure that all fastening nuts are snug CAUTION Fastening nuts as well as eyes are plastic and threads can strip easily AA Fastening Nuts e Check the air pressure to make sure it 1s set at 80 psi to100 psi e Check the air filter water trap Empty 1f full Weekly e Check the machine for smooth motion through a complete door cycle e Clean linear bearings and the chrome shaft with a clean dry cloth then lubricate 5 2 KVAL 994 X Operation Service Manual Maintenance Schedule e Inspect lock flow controls Adjust 1f required gt Adjustment knob EN lt q Tightening nut e Check all air lines amp electrical wiring for kinks or rubbing e Refill lubricator with an ISO 32 standard hydraulic oil use KVAL part SYS LUBEG Six Month Checkups e Wash filter and lubricator bowls with soapy water e Grease all bearings and tighten all bolts Access to some grease fittings is difficult and will require a special needle point grease tip supplied with your system e Clean and lubric

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