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Kval 558, Operation Manual

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Overview of the 558 Door Sizer

1-2

KVAL 558 Operation Manual

Overview of the 558 Door Sizer

The KVAL 558 Door Sizer is designed to 

resize 

doors to the correct width and bevel. This 

machine features a 5” cutter head with 50 mm replaceable inserts. The cutter head is spindle 
driven with a 5 HP motor and adjusts from a 0 degree to 3 degree bevel. Separate drives supply 
corner easements and sands the edge of the door to smooth finish. The machine will accommodate 
both interior and exterior doors up to 4 ‘wide with raised moulding on one or both door faces.

The feed system features drive wheels above and below, which automatically adjusts for door thick-
ness.

About this Manual

This manual is one of two manuals. The set includes this 

Operation Manual 

and a Service Man-

ual. 

The Operation Manual is directed toward operators of the machine. It includes identification of 
machine assemblies, power-up and power-down steps, operation and using the user interface.

The Service Manual is directed toward qualified service technicians. It includes maintenance and 
troubleshooting information.

TABLE 1. 

Title

Part Number

558 Door Sizer Operation Manual

DOC-201_1-OP

558 Door Sizer Service Manual

DOC-201_1_SRV

Summary of Contents for 558

Page 1: ...Innovation Quality Honesty Operation Manual Published 1 14 19 558 Door Sizer 558 Door Sizer Operation Manual ...

Page 2: ...f 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 http www kv...

Page 3: ... user experience with our product that is the manual the machinery the software etc What was easy or difficult to use or to learn If you could change something about the design what would it be Please email your comments and suggestions for improve ment to userexperience kvalinc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information abo...

Page 4: ...KVAL 558 Operations Manual ...

Page 5: ...ate 1 10 Getting Help from KVAL 1 12 On Line Help 1 12 Product Return Procedure 1 12 How to Download the Service Application 1 14 Download Application 1 14 Safety Sign Off Sheet 1 17 A Note to the Operator 1 17 Chapter 2 Operation of the 558 Chapter 2 at a Glance 2 1 Operator s Tour 2 2 Sensors 2 3 In Feed Eyes 2 3 Valve Bank 2 7 Cutter Easer and Sander 2 8 Identification of Electrical Panel Parts...

Page 6: ...reen 2 22 Description of the Setup Screen 2 26 2 29 Description of the Preset Setup Screen 2 30 Description of the Diagnostic Screen 2 30 Chapter 3 System IT Administration System IT Administration 3 2 About the 558 Computer 3 2 Connections on the PLC 3 2 Backing up the Computer 3 3 About Remote Connection to KVAL Service 3 3 ...

Page 7: ...ual 1 2 Safety First 1 3 Safety Sheet Sign Off Sheet 1 3 Safety Terminology of Labels 1 3 Safety Guidelines 1 3 Lockout Tagout Procedure 1 7 Follow the P R O P E R lockout rule of thumb 1 9 Zero Energy to Start Up 1 10 Zero Energy State to Start Up to Operating State 1 10 Getting Help from KVAL 1 12 On Line Help 1 12 Product Return Procedure 1 12 How to Download the Service Application 1 14 Downlo...

Page 8: ...p to 4 wide with raised moulding on one or both door faces The feed system features drive wheels above and below which automatically adjusts for door thick ness About this Manual This manual is one of two manuals The set includes this Operation Manual and a Service Man ual The Operation Manual is directed toward operators of the machine It includes identification of machine assemblies power up and...

Page 9: ...f Labels In addition to the nameplate KVAL machines may have other warning labels or decals that pro vide safety information to operators Safety labels should be clearly visible to the operator and must be replaced if missing damaged or illegible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if the wa...

Page 10: ...ne is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before performing any mainte nance or repairs on th...

Page 11: ...one supply located at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag ou...

Page 12: ...s machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed 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 Safe...

Page 13: ...c 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...

Page 14: ...vices 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...

Page 15: ...e such as the one shown here Follow the P R O P E R lockout rule of thumb P Process shutdown R Recognize energy type electrical pneumatic mechanical etc O OFF Shut off all power sources and isolating devices P Place lock and tag E ENERGY Release stored energy to a zero energy state R Recheck controls and test to ensure they are in the OFF state ...

Page 16: ...ease be advised that some com ponents of the machine may start automatically when energy is restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is started Perform Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the personnel alarm before s...

Page 17: ... 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 YOUR LIFE MAY DEPEND ON IT LOCKO...

Page 18: ...rs 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 4 1 for more information Product Retur...

Page 19: ...tarting other equipment etc How was the product configured in detail Which if any cables were modified and how With what equipment is the unit interfaced What was the application What was the system environment temperature spacing contaminants etc 3 Call Kval customer support for a Return Material Authorization RMA When you call Have the packing slip or invoice numbers available Have the documente...

Page 20: ...2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Google web...

Page 21: ... Field Enter your name The KVAL tech nician will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connec tion to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support App is loaded and completed call the KVAL service center 1 800 553 5825 ...

Page 22: ...How to Download the Service Application 1 16 KVAL 558 Operation Manual Page Intentionally Left Blank ...

Page 23: ...w my company s safety procedures I have read and understand these guidelines Machine Safety Concerns I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the electrical...

Page 24: ...Safety Sign Off Sheet 1 18 KVAL 558 Operation Manual ...

Page 25: ... 588 Ser vice Manual Chapter 2 at a Glance Operator s Tour 2 2 Sensors 2 3 Valve Bank 2 7 Cutter Easer and Sander 2 8 Identification of Electrical Panel Parts 2 9 Description of the Six Light Panel 2 10 Snapshot of Door Cutting Process 2 11 Basic Operation 2 12 How to Power up the 558 2 12 About Homing of the 558 2 13 How to Power Down the 558 2 14 Emergency Shutdown and Recovery 2 14 Description ...

Page 26: ...ed Out Feed Cutter Motor Easer Motors x2 Sander Motor User Interface Electrical Panel Location of Six Light Panel Valve Bank Sensors located at the In Feed the Out Feed and down the length of the 558 Push Over Cylinder Servo Width Adjustment Width Adjust Fence Front Back Width Adjust Fence Air Blow Off FIGURE 2 2 Top View of 558 Door Sizer System ...

Page 27: ... Keep the photo eyes of the sensor clean and unblocked Optical Eye Sensor Ferrous Proximity Sensor cylinder FerrousProximity Sensor width adjust FIGURE 2 3 Examples of Sensors In Feed Eyes The In Feed eyes sense that a door is loaded The eyes perform different functions Door Sense Eye Senses a door is loaded Movable Fence Inside Eye Senses door and sends signal to control inside fence Movable Fenc...

Page 28: ...achine Eye Before Wheel 2 I 0014 FIGURE 2 5 Location of Mid Machine Eyes TABLE 2 Description of Machine Eyes Location Call Out Number Description Before Wheel 1 I 0013 Push over control when activated Before Wheel 2 I 0014 Stops door before cutter Before Wheel 2 I 0015 Brings Wheel 2 down to secure door when blocked wheel goes up when clear Before Wheel 3 I 0016 Brings Wheel 3 down to secure door ...

Page 29: ...on of Out Feed Eye Home Sensor Width Limit Sensors The width adjust is determined by ferrous proximity sensors The home eye sets the zero reference of the calibration The open and the close sensors set the minimum and maximum travel limits for that axis Servo Width Open Limit I 0002 Servo Width Home Sensor I 0001 Servo Width Close Limit I 0003 Push Over Cylinder FIGURE 2 7 Location of Width Adjust...

Page 30: ...in the cylinder assembly Note If the zero or three degree bolt needs to be adjusted the sensor will need to be adjusted to correspond with the change Refer to the KVAL 558 Service Man ual for information on adjusting the Zero and Three Degree Bolt Zero Degree Sensor Triggered when the Pis ton is extended I 0004 Three Degree Sensor Triggered when the Pis ton is Retracted I 0005 FIGURE 2 8 Zero Degr...

Page 31: ...he Drive Wheel valves are activated the top red lights will turn on When the Three Degree valve is activated the bottom green light will turn on When the Zero Degree valve is activated the top red light will turn on Drive Wheel 1 Q 0001 Drive Wheel 2 Q 0002 Drive Wheel 3 Q 0003 Terminal Block Manifold Base Blow Off Q 0007 In Feed Push Over Q 0000 Drive Wheel 4 Q 0004 Zero Degree Top Red Light Q 00...

Page 32: ...w are the front and rear view of the Cutter Easers X2 and the Sander Rear View Front View Cutter Head Easer Router Bit Cutter Motor Easer Motor 2 of 2 Sander Motor Sanding Belt Easer Motor 1 of 2 Direction of Motor Rotation FIGURE 2 10 Front and Rear View of Cutting Assembly ...

Page 33: ...y protocol as described in Chapter 1 24 V 90 W Power Supply ACR Relay Three Phase Input PDRRelay 3 Pole Contactor Top Easer Motor VFD Control Transformer Drive Wheels VFD CutterMotor VFD Beckhoff Computer and PLC USB to RJ 45 adapter Width Adjust Servo Amplifier Sander Contac tor and Over load Circuit Bottom Easer Motor VFD Fixed Fence VFD Sander Motor VFD 5 0 V 12 5 W Power Supply Q 0010 Relay OK...

Page 34: ...p 4 Stop 5 Start 6 24VDC Control Power light illuminates when the Control Transformer is pulled out and the power is working on secondary side of Overload Relay The overload circuit for the Sander is working when light E Stop The back gate is closed and Frame E stop is not acti vated when this light is on 24VDC light comes on once the ACR is latch and the 24VDC power Supply Stop This light will be...

Page 35: ...rmer Home Machine Sizing or Feed Thru Press Feed Thru so it displays Feed Through Enabled Auto Width or Manual Width Press Auto Feed so it displays Auto Feed Mode Press Auto Width so it displays Auto Width Enabled Press Auto Width so it dis plays Auto Width Disabled A Width must be entered before each door enters the 558 Ready to Process Doors Manual Width Auto Width Sizing Feed Thru ...

Page 36: ...art Up screen to display 4 Remove any door in the feed system Make sure area is clear 5 Press the Home Machine button to home the machine and set the reference for the machine Control Transformer Pull out the control knob to turn ener gize the system Push the knob in to de ener gize system Machine Start Stop Push the Green Start button to start the machine operation Push the Red Stop button to sto...

Page 37: ...8 is re set the homing routine must be performed again to reset the zero reference The routine is as follows 1 Press Home Machine Button 2 Fence slowly opens scanning for homing eye 3 When it finds the eye it stops 4 The fence then very slowly starts closing moving off the eye The reference loca tion is stored when it comes off the eye 5 Fence then moves into position Home Sensor Fence Opens to fi...

Page 38: ...wer surge resulting from an electrical storm Step 1 Step 2 Step 3 Emergency Shutdown and Recovery In case of emergency push the Control Transformer button to stop the operation of the machine When an control transformer button is activated cutting stops the door un clamps all motors deactivate and all I O power is killed Warning High Voltage is present in this panel at the top of the three phase i...

Page 39: ... station 4 Home KVAL 558 After this the machine should be ready for normal operation If Safety Gate is Opened During Run At the back of the 558 is a safety gate on the security fence If the gate is opened the effect is the same as pushing the stop button or pushing the touch screen system off button To recover secure gate and restart machine Note It is not necessary to Re Home the machine if gate ...

Page 40: ...he door cutting process auto run and manually run the door store door profiles and use diagnos tics to help troubleshoot the 558 The user interfaces include the following Main Screen Manual Screen Setup Screen includes Preset Screen Diagnostic Screen Main Screen The Main Screen is the start up and primary interface for the operator It contains the necessary controls to run a door through the cutti...

Page 41: ...tup on page 2 32 Input Window has been added to the Preset Screen See Description of the Preset Setup Screen on page 2 31 Cut Offsets Cut Offsets is a Remodel Door replacement A positive number will result in a nar rower door 1 Enter desired offset values on the Cut Offsets Setup screen The values will be dis played as active buttons on the main screen See Offset Setup on page 2 32 2 At the Main S...

Page 42: ...ed Through Disabled Uses the preset setting and width adjust Feed through Offset set in the Setup Screen to open the width adjust by the offset amount so a door can be fed through the 558 without being machined Auto Width Mode Click the button to toggle between Enable and Disable Auto Width Enable will scan the door as the door feeds in and automatically snap to the closest matching preset size Au...

Page 43: ...ter the desired width of the door Thickness To enter measured thickness of the door click the white box and enter the desired thickness of the door Note The manual entered thickness number will override the 1 3 8 1 3 4 buttons To use standard thicknesses supplied by the interface fol low the steps below Click the 1 3 8 box if door thickness is 1 3 8 thick Click the 1 3 4 box if door thickness is 1...

Page 44: ...nge in the Preset Selection matrix located on the Main Screen See Description of the Setup Screen on page 2 26 Home Machine This button starts the home sequence on the machine which causes the movable fence to slowly scan to find a physical refer ence point on the frame When this point is found its position is stored and then used to calculate the location of all moves after this The home sequence...

Page 45: ...wn System This button only shuts down the computer Machine Status Feedback The top left corner box displays the status of the machine Tip If the machine does not per form a function look at this box first when trouble shooting Top Line indicates the machine status Feed indicates the condition of the feed circuit Head indicates if the Cutter is ON or OFF Description of User Interface Screens 2 21 K...

Page 46: ...wn in the feedback box should be within 1 8 of actual width of the door as it feeds into the 558 If the width displayed is more than 1 8 than the door go to the Set Up Screen and calibrate the Auto Width Eye See Auto Width Eye on page 2 28 Preset Selections This selection of buttons allows a quick way to load the preset widths of a saved door The preset values are created in the Preset Menu See on...

Page 47: ...Interface Screens 2 23 KVAL 558 Operation Manual Manual Screen The Manual Button opens the Manual Screen The Manual Screen interface allows the operator to manually control machine speed direction and width servo position ...

Page 48: ...k the white box and enter the open and close speed of the carriage The range is 1 to 100 Use the number pad to enter the desired speed and press OK when finished Setup Mode Click the button to toggle between Enable and Dis able Setup Mode Disabled Runs the cutter mode nor mally Setup Mode Enabled This will open the width adjust carriage a half inch The door feeds through the 558 normally except al...

Page 49: ...button toggles between feeding the door at full speed and feeding at slow speed Fixed Speed Cutting Speed This button toggles between running at the fixed preset speeds and the cutting speed set by the speed potentiometer Feed Wheels Feed Wheels Up Feed Wheels Down This button toggles the Feed Wheels up and down Auto Width Mode Refer to Auto Width Mode on page 2 18 for Auto Width description Descr...

Page 50: ...2 18 Exit Application Click the button to exit out of the 558 program and go back to the Windows CE desktop Description of User Interface Screens 2 26 KVAL 558 Operation Manual Description of the Setup Screen From the Setup Screen the operator can make general adjustments and calibration adjustments ...

Page 51: ...Description of User Interface Screens 2 27 KVAL 558 Operation Manual ...

Page 52: ...umber pad will be displayed 3 If the feedback Measured Width number is less than the actual door width enter a posi tive number then click the check mark 4 If the feed back Measured Width number is greater than the door width enter a negative number then click the check mark 5 Once this is done click Main button and select the preset width and re run the door Repeat steps 3 5 until Measure Width i...

Page 53: ...is number is combined with the Base number click on to Offset A number pad will be displayed 3 If the width of door is narrower than the Width Number take the difference and enter that as a positive number in the big white box under 0 Calibration 4 If the door width is larger than the Width number enter the difference as a negative number 5 Once this is done click Main button and select the preset...

Page 54: ...o open during the feed thru process See Feed Through Mode on page 2 18 Note This feature is rarely used and default offset should be left in the box Remodel Door Offset Click the white box under the title to enter the Remodel door offset number This offset combines with all the presets when the Remodel Door Button is enabled See Remodel Mode on page 2 20 Description of User Interface Screens 2 30 ...

Page 55: ... button that needs to be updated 2 A number pad will be displayed Enter the desired door width num ber for that preset 3 Click the OK button at the top right corner of the number pad 4 The width amount will reflect on the title of the button 5 The preset in now set to the new door width 6 Follow steps 1 through 4 for each preset that needs to be updated Input or Change Presets Input Window Interfa...

Page 56: ...change or setup an Offset value follow the steps below 1 Click the offset button that needs to be updated 2 A number pad will be dis played Enter the desired offset 3 Click the OK but ton at the top right corner of the number pad 4 The offset value will be reflected on the buttons located on the Main Screen 5 Follow steps 1 through 4 for each offset that needs to be updated ...

Page 57: ...will have the most current routine that is running Read the error and if the problem is not resolved call KVAL Inc 1 800 553 5825 and let the KVAL representative know the error code that is displayed on the machine so the down time can be very minimal Tip In trouble shooting the machine first look in the top left corner and read the status of the machine If that doesn t solve the problem then read...

Page 58: ...Description of User Interface Screens 2 34 KVAL 558 Operation Manual ...

Page 59: ...computer that sup plies the user interface and controls the operation of the machine With the controller KVAL can remotely help troubleshoot your machine Chapter 3 at a Glance System IT Administration 3 2 About the 558 Controller 3 2 Connections on the PLC Controller 3 2 Backing up the Computer 3 3 About Remote Connection to KVAL Service 3 3 ...

Page 60: ...he module also contains internal main memory The computer has a removable Compact Flash card from which it boots The controller uses a Windows CE operat ing system with TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include A smart power supply to connect to EtherCat terminals This supply contains a LCD to display system and user messages A DVI USB modu...

Page 61: ...alinc com Some basic information for backing up the system are Files are located in HardDrive TwinCAT Boot Two recommended methods of backup Remove and duplicate Compact Flash card at regular intervals Create a copy of HardDrive TwinCAT Boot folder About Remote Connection to KVAL Service Remote access is a powerful tool to help fix issues that occur with the 558 machine With the remote access our ...

Page 62: ...System IT Administration 3 4 KVAL 558 Operation Manual ...

Page 63: ...scription 2 8 location 2 8 cutter motor location 2 8 D diagnostic screen description 2 30 door cutting process flow chart 2 11 summary 2 11 DVI USB module location 3 2 E easer motors location 2 8 easers location 2 8 electrical panel part locations 2 8 e stop light description 2 10 EtherCat smart power supply 3 2 terminals location 3 2 ethernet module connection to servo amplifiers 3 2 exit applica...

Page 64: ...er 1 2 manual screen auto feed mode 2 25 auto width mode 2 24 description 2 22 feed speed and direction button 2 24 feed through mode 2 25 feed wheels button 2 24 setup mode button 2 23 speed button 2 23 width servo position button 2 23 O out feed eye 2 5 out feed eye sensor location 2 5 out feed sensor description location 2 5 overload relay light description 2 10 P part number manual 1 2 parts a...

Page 65: ...t 2 29 remodel door offset button 2 29 six light panel description 2 10 sequence list 2 10 speed software button description 2 23 start light description 2 10 stop light description 2 10 T tagout procedure 1 7 thickness software button description 2 18 three and zero degree sensors description location 2 6 three degree calibration description 2 28 three degree calibration using setup screen 2 28 T...

Page 66: ...Notes ...

Page 67: ...Notes ...

Page 68: ...partment Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL Phone and Fax In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email service kvalinc com http www kvalinc com ...

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