Kval 965X Page 70 Service Manual Download

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Troubleshooting Basics

4-4

965X Service Manual

Determine What:
What Subsystem is Respon

sible for the Failed Sequence

Step.

Analyze the subsystem:
Check the Load.
Check the Position Feed Back.
Check the Positioning System

Typical Machine

Sequence

Responsible Sub

system

1. Move Door into Posi

tion

Feed System

2. Clamp the Door

Door Clamp

3. Make the Cuts

Cutter Position

ing Cutter Power

4. Unclamp the Door

Door Clamp

5. Move Door Out

Feed System

6. Wait for Next Door

Feed System

Basic Troubleshooting Steps

Determine Where:
The Sequence Step Where

the Failure Occurs

What was the Machine Trying to Do?
What Was the Machine Trying to Do Next?
Check the Sequences in the Table Below.

How is the Broken Section Suppose to Work?

What is Keeping the Broken Section From

Working?

What Part of the Machine is not Working?
Check the Subsystems in the Table Below.

Ask

Narrow

Verify

Summary of Contents for 965X

Page 1: ...Innovation Quality Honesty Service Manual Published June 10 2021 965X Jamb Machining System With KvalCAM Service Manual 965 X System ...

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

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

Page 4: ...KVAL 965 X Service Manual ...

Page 5: ...er 1 11 Lockout Tagout Air Supply 1 12 Start Maintenance 1 12 Post Maintenance Steps 1 12 Zero Energy to Start Up 1 13 Getting Help from KVAL 1 15 On Line Help 1 16 How to Download the Service Application 1 17 Download Application 1 17 Safety Sign Off Sheet 1 20 A Note to the Operator 1 20 Chapter 2 System IT Administration System IT Administration 2 2 About the 965X Line Computer 2 2 Connections ...

Page 6: ...ilter and Lubricator Bowls 3 10 Maintenance NO GOES 3 11 Lubrication Schedule 3 12 Typical Lucubration Kit 3 12 Lubrication Requirements 3 13 Pillow Block Bearing Housings 3 13 Flange Bearing Housings 3 14 Ball Rail Bearing 3 14 About Taper Bearings 3 15 Tapered Bearing Housings 3 15 Ball Screw Nut 3 16 Ball Screw Drive Assembly 3 16 How to Prepare the 965X for Greasing 3 17 Cutter Head Location A...

Page 7: ...ting Basics 4 3 Before you Adjust 4 3 Analyze the Sub Systems 4 5 About Motion Control 4 6 Sequencing 4 6 Point to Point 4 6 Incremental 4 6 Basic Control Circuit 4 7 About a Typical Contactor Control 4 8 About Contactor Troubleshooting 4 9 About Typical VFD Motor Drive Control 4 10 About the VFD 4 11 About VFD Troubleshooting 4 12 About a Typical Pneumatic Circuit 4 13 Typical Pneumatic Assembly ...

Page 8: ...965X Servo Motor Locations 4 21 About Switches and Sensors 4 22 Using Sensors to Trouble Shoot 4 23 Sensor Locations on Machine 4 23 Frame Sensors 4 23 Cutter Head Sensors 4 24 Troubleshooting Electrical Problems 4 25 If the Power Stops During Normal Operation 4 25 Description of the Light Tower 4 27 ...

Page 9: ...ptions page 1 2 Safety First IMPORTANT safety information is described in this section page 1 6 Lockout Tagout Guidelines Procedures describing Lockout Tagout page 1 10 Zero Energy to Start Up Procedure to power up your machine for the first time page 1 13 Getting Help from KVAL This section describes the method to con tact the KVAL service center for help The section includes how to get informati...

Page 10: ...each adding unique functionality to the machine CNC Functionality The 956X a 3 Axis x y z CNC machine provides the operator with the ability to dictate mortise pattern depth radii location as well as pre drill pattern and depth Each variable is easily modi fied via our touch screen and KvalCAM program Key components include Beckhoff AC servo motors controller and industrial computer which in turn ...

Page 11: ...ndles are combined with tool path programming to eliminate chipping at the jamb edge A third hi fre quency 1 5HP spindle is utilized as a point to point pre drill system for hardware application Chisels The 965X is equipped with four 4 chisels mounted in pairs for the square hinges for higher end markets Safety An electronic zone sensor is included to prevent access to the machine while routers ar...

Page 12: ...fety Information 2 Operation Inter face Descriptions of how to power machine line and operator inter face user screens 3 Calibration Descriptions of Calibration Rou tines and how to use the interfaces 4 Tour of 965X Identification and descriptions of the 965X machine assemblies Chapter Title Description 1 Introduction Safety Information 2 System IT Admin istration Descriptions of the PLC system an...

Page 13: ...65X Service Manual KvalCAM Reference Manual Chapter Title Description 1 KvalCAM reference Description of the Interface 2 KvalCAM Examples Examples of Common Door Job Features 3 KvalCAM Common Terms Common terms associated with KvalCAM ...

Page 14: ...r illegible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if the warning is not heeded it can cause death or serious injury CAUTION means if the precaution is not taken it may cause minor or moderate injury Safety Guidelines In addition to the caution and warning labels affixed to this machine follow ...

Page 15: ...ver perform any maintenance unless machine is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before perf...

Page 16: ...t 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 out or lock out the el...

Page 17: ...you believe any part or operation of this machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed 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...

Page 18: ...tag on each disconnect Only each operator may remove their own lock and tag Important When many people are all working on the same machine you will need a multiple lockout device such as the one shown here Follow the P R O P E R lockout rule of thumb P Process shutdown R Recognize energy type electrical pneumatic mechanical etc O OFF Shut off all power sources and isolating devices P Place lock an...

Page 19: ...ly and pressure spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shutdown 3 Obtain locks keys and tags from your employer s lockout center 4 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to pop it out...

Page 20: ...ompletely removed and that all guards and safety devices are installed 10 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 11 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 12 The tags must be destroyed and the ...

Page 21: ...n 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 y...

Page 22: ...work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect ...

Page 23: ...print number 2 Contact our customer support team In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email address is service kvalinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday What is the extent of the failure reason for return What are the relev...

Page 24: ...stomer support for a Return Material Authorization RMA When you call Have the packing slip or invoice numbers available Have the documented reason for return available 4 Send the merchandise back to Kval Make sure the item s you are returning are securely packaged and well protected from shipping damage Include the packing slip or invoice numbers Include the documented reason for return Include th...

Page 25: ...t 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 br...

Page 26: ...am is ready to allow technicians to access machine computer Your Name Field Enter your name The KVAL techni cian will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connection to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support App ...

Page 27: ...How to Download the Service Application 1 19 965X Service Manual Page Intentionally Left Blank ...

Page 28: ...y 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 po...

Page 29: ...ply the user interface and control the operation of the machine Chapter 2 at a Glance Section Name Summary Page System IT Administration This section describes the basic parts of the operation of the PLC in the machine Such as About the PLC Connections on the PLC Backing up the Computer About Remote Connection to KVAL Service page 2 2 ...

Page 30: ...U module as a PLC Programmable Logic Controller In addition to the CPU and the chipset the module also contains internal main memory The com puter has a removable Compact Flash card from which it boots Each controller utilize a Win dows based operating system with TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include A smart power supply to connect to ...

Page 31: ...bes maintenance on the machine The maintenance is broken into machine cycle times and describes the sug gested maintenance steps to perform 300 Cycles 600 Cycles 3 000 Cycles 12 000 Cycles 72 000 Cycles page 3 2 Lubrication Requirements This section describes the lubrication require ments for the machine including types of lube to use This section includes Linear Bearings Flange Bearing and Pillow...

Page 32: ...may not pertain to all machines 300 Cycles Clean Use pressured air to blow off dust and debris on entire machine Clean Blow out dust collection cans 600 Cycles Inspect Air Pressure Gages Adjust if necessary to the proper PSI located on the label Adjust only if Trained in Maintenance Inspect Inspect Air Filter Water Traps Empty if necessary Inspect Inspect the Tooling for wear Drill Bits Cutting To...

Page 33: ...dry cloth 12 000 Cycles Inspect Inspect all air cylinders for air leaks Replace if seal is leaking Inspect Inspect hydraulic lines for loose fittings leaks and cracks Inspect Inspect ball rail shafts for pitting or abrasions Lubricate Clean and lubricate all slides and cylinder rods with dry silicone spray Lubricate Lubricate all bearing shafts with silicone and clean rag 72 000 Cycles Inspect Ins...

Page 34: ... issues with the operation of the machine Use pressured air to blow off dust and debris on entire machine Use a clean rag to clean areas not affected by pressurized air Also blow out any dust collection units Check vertical bearings for loose screws Loose screws could cause bearing damage FIGURE 3 2 Dust Buildup Spots High Dust Accumulation Areas Dust Collection Unit ...

Page 35: ...essure Gages Adjust if nec essary to the proper PSI located on the label Adjust only if Trained in Maintenance Inspect Air Filter Water Traps Empty trap if necessary Slide locking switch down to unlock twist trap to remove Reverse action when installing trap Inspect the Tooling for wear Drill Bits Cutting Tools See Remove and Replace the Router or Pre Drill Bits on page 3 27 ...

Page 36: ...ection Units Check and empty any dust collection units Clean any dust filters Dust collection systems vary from machine to machine Follow manufacturers directions to empty dust collection units FIGURE 3 3 Typical Dust Collection Unit Filters Dust Collection Con tainers ...

Page 37: ... switch for cracks in the body and check that the switch arm actuates clicking sound when moved to the extreme Note Depending on the model of limit switch the amount of pre travel amount of movement from the arms resting position is either 5 or 20 degrees before the limit switch actuates Inspect all airlines for kinks rubbing and leaks Perform pull test on push on hose connectors Check all airline...

Page 38: ... Grease Ball Screw Bearings Grease ball screw bearings if applicable For a table of lubrication types to use Lubrication Schedule For locations to lubricate See Grease Ball Screw Bearings Clean Bearing Shafts Clean all bearing shafts with clean dry cloth Spray shaft with silicone oil and clean build up grime and dirt Slide locking switch down twist bowl and remove Refill bowl Reverse action when i...

Page 39: ...s include a cylinder not extracting or retracting to the limits Cylinders not holding their position Inspect Ball Rail Shafts and Ball Screws Inspect ball rail shafts for pitting or abrasions Inspect ball screws for pitting or abrasions Clean and Lubricate Slides Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray Example of a Pitted Ball Rail ...

Page 40: ...t the hardware is tight Electrical Check all connections in each node box and electrical panel Wires may become loose due to vibration Check contactors for wear Computer Backup Backup computer software Wash Filter and Lubricator Bowls Wash filter and lubricator bowls with soapy water Slide lock down to unlock Twist bowl to remove it Remove filter from Air filter assembly Inspect and clean or repla...

Page 41: ...ditions are changed timing accuracy or damage may occur during the machine process Do not adjust air PSI above or below factory settings Do not adjust any and all flow controls from factory settings Do not remove shim stock Do not Change or Alter any safety assemblies E Stops Gate Locks etc Do not Change programs in PLC s or PC s Do not Alter Electrical Components ...

Page 42: ...e Block Bearing Ball Screw Every 80 Hours of Machine Operation Tapered Bearing Once 4 X a Year Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Note Some CNC Machines drop every 5 10 cycles Either lubricant listed below is approved to use KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32 Gulf Harmony...

Page 43: ...ng is basically a valve that opens under pressure to allow lubricant to pass through a channel and be forced into the voids of the bearing When the pressure stops the ball returns to its closed position The ball excludes dirt and functions as a check valve to prevent grease escaping back out of the fitting The ball is almost flush with the surface of the fitting so that it can be wiped clean to re...

Page 44: ...ble operation FIGURE 3 5 Flange Bearings Ball Rail Bearing Ball Rail Bearings are linear bearings that are attached to positioning rails In most cases the bear ings are attached to assemblies to move them in the X Y or Z direction FIGURE 3 6 Ball Rail Bearings Greasing Flange Bearing Bearing Housings Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 250 h...

Page 45: ...n asset that the bearing blocks often require little maintenance for the life of the machine FIGURE 3 7 Sample of Tapered Bearing Tapered Bearing Housings The taper bearings differ from other machine bearing assemblies in that they are in a sealed envi ronment To identify a Tapered Bearing Housing look at the enclosure and verify there are seals between the screw and the housing FIGURE 3 8 Tapered...

Page 46: ... Ball Nut Ball Screw Drive Assembly Including the Ball Screw Nut other types of bearings may be included on the assembly Figure 3 10 shows a typical Ball Screw Drive Assembly FIGURE 3 10 Ball Screw Drive Assembly Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 80 hours of operation Ball Screw Nut Housing Ball Screw Drive Greasing Ball Screw Nut Servo Mo...

Page 47: ...f the machine 1 At the Main screen Select the Park button to drive the head to the end of the machine 2 Perform Lockout Tagout 3 Follow instructions to grease the bearings See Grease Locations for the 965X on page 3 18 Cutter Head Location After Park The Cutter Head will move to the end of the machine after the Park button is selected FIGURE 3 11 Park the Cutter Head ...

Page 48: ... fittings and apply EP 2 grease 4 After lubrication is completed reverse Lockout Tagout FIGURE 3 12 Cutter Head Bearing Locations This machine is a powerful electro mechanical motion control system If servicing this machine fol low the safety guidelines Failure to do so can result in damage to equipment and or serious injury to person nel Shutdown the machine and follow the Lock Out Tag Out proced...

Page 49: ...to Use an extender to reach tight areas 1 Park the Cutter Head see How to Prepare the 965X for Greasing on page 3 17 2 Perform Lockout Tagout 3 Remove cover 4 Identify zerk fittings and apply EP 2 grease See Figure 3 13 on page 3 19 Jamb Stop Bearings can be accessed from the side 5 After lubrication is completed re install the cover 6 Reverse Lockout Tagout FIGURE 3 13 Carriage Head Grease Points...

Page 50: ... clamp assembly The machine has a ten clamp assemblies with vertical and horizontal rail bearings 1 Park the Cutter Head see How to Prepare the 965X for Greasing on page 3 17 2 Perform Lockout Tagout 3 Identify zerk fittings on each clamp assembly and apply EP 2 grease 4 After lubrication is completed reverse Lockout Tagout FIGURE 3 14 Bearings on the Clamp Assemblies X1 Horizontal and X2 Vertical...

Page 51: ... Park the Cutter Head see How to Prepare the 965X for Greasing on page 3 17 2 Perform Lockout Tagout 3 Identify zerk fittings on each servo assembly and apply EP 2 grease 4 After lubrication is completed reverse Lockout Tagout I FIGURE 3 15 Location of Servo Motors Z Motor Servo Assembly Tapered Bearing Ball Screw Nut X Axis Motor Self Lubricating See Replacing the Self Lubrica tor on page 3 32 Y ...

Page 52: ...vers the lubricated air to valve banks and air cylinders FIGURE 3 16 Typical Air Line Filter and Lubrication System Adjusting the Air Line Lubricator Using the knob on the top of the lubricator adjust until one drop per every other cycle is used as observed through sight glass Shop Air Input Air On Off Muffler Filter purge Pressure Gauge with adjust Lubricator Lubricated Air Output Clean Dry Air C...

Page 53: ... 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 li...

Page 54: ...IGURE 3 18 Tool Information Edge Cutter Motor Most Common Tool a a Most Common Tools Some bits may differ due to special cutting processes Collet Motor P N KVAL Collet Wrench PN KVAL Shaft Wrench PN 1 Chisels Sip013 N A N A N A N A 2 Drill JLD1250 COLER20 02 COLSE55E389 1 5 HP COLKEYER20S WRENCH22MM 3 Router SOU SRU606SL COLER25 08 COLS73E478 3D 3 HP COLKEYER25MINI WRENCH24M 4 Router RBSC0808350 L...

Page 55: ...the recom mended values See Collet Torque Values on page 3 34 FIGURE 3 19 Too Set This machine is a powerful electro mechanical motion control system If servicing this machine fol low the safety guidelines Failure to do so can result in damage to equipment and or serious injury to person nel Shutdown the machine and follow the Lock Out Tag Out procedures Caution ...

Page 56: ...hine and follow the Lock Out Tag Out procedures 2 After machine is locked and tagged out remove the access plate by loosening and re the knurled knob screws from the front cover 3 Put the access plate and retaining screws aside Note Remove full Carriage Coverto replace Chisels FIGURE 3 20 Remove Cover Plate ...

Page 57: ...ckout Tagout procedures as detailed in the safety section of Chap ter 1 of this manual 1 Use a 17 mm shaft wrench and a 3 8 collet wrench to remove the bit on the pre drill or router assemblies See Figure below FIGURE 3 21 Removing Pre Drill or Router Bit 2 Inspect and clean collet assembly FIGURE 3 22 Collet Assembly Collet Spindle Collet Nut Verify that there is no damage or bluing on the side o...

Page 58: ...ip of the bit Note If available and suits the parameters of the tool length use Bit Depth Gauge PN 432 C to set the depth See Figure 3 23 FIGURE 3 23 Using the Bit GaugesFigure 3 23 6 Lightly tighten and torque to correct value For torque values See Collet Torque Values on page 3 34 7 Before starting the cutting process check the Tool Configuration screen at the inter face See Check or Update Tool...

Page 59: ...or Update Tool Configuration To display the Configuration Screen select the Tool Config tab and choose the desired tool 1 Select the Tool Config tab at the Operator s station 2 Select the desired tool 3 Validate the tool specifications FIGURE 3 24 Configuration Panels ...

Page 60: ...lled out of their retracted position to work on the chisel s 3 Remove covers to access the chisels Important Be alert that all tools in the assembly are sharp and can cause injury 4 Using a 7 16 wrench loosen and remove the bolts retaining the chisel clamps Remove the clamp and chisel This machine is a powerful electro mechanical motion control system If servicing this machine fol low the safety g...

Page 61: ...ce the new chisel in the fixture add the clamp and tighten down the bolts back onto the clamp 7 Verify that the chisel does not wobble in the fixture after tightening Chisels should be rigid and straight in the assembly 8 Push the chisel cylinder back into the machine head 9 Before starting the cutting process check the Tool Configuration screen at the inter face See Check or Update Tool Configura...

Page 62: ... user screen when oil is low 5 The alert is a 30 day warning but it is recommended to change it as soon as possible Refer to Electrical Drawing for connections labels FIGURE 3 27 Location of Gear and Lubricator Replace the Lubricator Well The lubricator kit part number is Wit Lubricating Kit It contains lubricator well hose with oil and its connectors bracket and sensor Follow the instructions on ...

Page 63: ...ose from the bottom of lubricator well and the applicator 10 Attach the new hose to the new well and the applicator 11 Bracket the new well against the machine 12 Slide the black and red wires into the connector Secure with a small screw driver 13 Polarity is not an issue but for consistency replace wires as they were 14 Route sensor wires to the corresponding node and connect to the correct termi...

Page 64: ...ue Values 3 34 965X Service Manual Collet Torque Values KVAL recommends torquing the collets Torquing adds consistency is important for repeatable machining Follow the torque tool manufacturers method of torquing ...

Page 65: ...Collet Torque Values 3 35 965X Service Manual ...

Page 66: ...Collet Torque Values 3 36 965X Service Manual ...

Page 67: ...s analyzing sub systems to desig nate a starting point for troubleshooting page 4 3 About Motion Control This section contains basic information on the operation of motion control circuits Includes dia grams of the control circuits page 4 5 Describing Control Circuits These sections describe the operation of the Contactor VFD Pneumatic Controls and Servo Drives page 4 8 to page 4 20 Using Sensors ...

Page 68: ...e At the Operators interface a shortcut is provided to enable live contact with the Kval Service Technician Tools Needed for machine hardware troubleshooting Access to a broadband internet connection An iPhone or Android smart phone We use Apple FaceTime or Google Duo for video A DMM A standard tool set For machine software troubleshooting Access to a broadband internet connection A computer runni...

Page 69: ...the router not cutting Is the cut out of specification Verify Verify or analyze the subsystem assembly that is responsible for the issue For example How is the subsystem supposed to work What is keeping the subsystem from working 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 fo...

Page 70: ...amp 3 Make the Cuts Cutter Position ing Cutter Power 4 Unclamp the Door Door Clamp 5 Move Door Out Feed System 6 Wait for Next Door Feed System Basic Troubleshooting Steps Determine Where The Sequence Step Where the Failure Occurs What was the Machine Trying to Do What Was the Machine Trying to Do Next Check the Sequences in the Table Below How is the Broken Section Suppose to Work What is Keeping...

Page 71: ... are the correct photo eyes limit switches or ferrous sensors activated Check the con troller 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 Photo Eye Bad element or bad cable Limit Switch Stuck or failure Wiring Broken worn insulation PLC Bad input port 4 Check th...

Page 72: ... 6 Wait for the next door Point to Point Point to point motion control involves moving a load from one fixed position to another fixed position at a constant speed and along one line axis X Y or Z A typical point to point would be a drill with a fixed depth The drill is either retracted or extended using a pneumatic cylinder Typically the drills travel is limited by physical stops Incremental Incr...

Page 73: ...the humans and the machine Examples A touch screen a PC or a button panel The Controller Translates entered information into a form the positioning system can understand Listens to the machine s other subsystems waiting for the OK to move command Sends the positioning instructions to the positioning system Listens to the positioning system for position status if there is a feedback loop Tells the ...

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

Page 75: ...circuit See Description of the Light Tower on page 4 27 1 Open the Main Electrical Cabinet to find the Contactor Thermal Overload Assem bly 2 Press each Green Reset button on the Thermal Overload An audible click will be heard on the tripped circuit Take note of tripped circuit 3 Once the overloads are reset verify LED s are on 4 Rerun the machine and verify that motor runs without tripping the ci...

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

Page 77: ...am see Figure 4 32 on page 4 10 FIGURE 4 33 Sample of VFD VFD models vary in KVAL machines depending on where it is used voltage requirements and type of PLC used This is a general view on the VFD See the machine s Electrical Print for detailed information Line Voltage IN Converted Signal OUT to Motor Operation Panel Access to manual operation VFD This panel can be used for trouble shooting purpos...

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

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

Page 80: ... solenoid body Use this information to troubleshoot system if nec essary FIGURE 4 37 Solenoids in Manifold Air Input Cylinder Retract Cylinder Extend Electrical Wiring Box Contains inputs from PLC to Coils Solenoids Manifold Base to accept air input and output air Coil Solenoid Receives input 24V from PLC to open a port Solenoid type will vary with machine application Common controls include an op...

Page 81: ... the process to move a router to the extend and the retract position with a double valve Extend Process If PLC determines the conditions are right to extend the Router 1 The PLC applies the control voltage to the Control Valve which directs com pressed air to extend port of the Cylinder 2 The Cylinder and Router are extended deactivating the Retract Sensor 3 The Router fully extends activating the...

Page 82: ...der and Router retract deactivating the Extend Sensor 3 When the Cylinder and Router are fully retracted the Retract Sensor is activated 4 The PLC senses the voltage from the Retract Sensor completing the process Positioning System Load Force Translated Positioning PLC Instructions Position Feedback Extend Sensor Retracted Sensor Deactivated Activated 24 Volts Extended Cylinder 24 V Applied Router...

Page 83: ...nd flipping screws in Hoppers However sometimes machine settling mechanics be broken in may be cause to slightly adjust extend and retraction speed If more than 1 2 turn on adjustment knobs are needed call in a specialist or check with KVAL customer service at 1 800 553 5825 Cylinder 0 V Router Assembly Load Position Feed Back Air In Control Valve Retract Sen sor Acti vated Air Pressure Retracts C...

Page 84: ...965X Service Manual Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Tip If Installing a new flow control assembly shut down the flow control and back out 4 to 5 turns this position is a good starting point for kine adjust ...

Page 85: ...e or a low voltage to a control coil Con trols for example are extending and retracting router drill clamping a door Valve banks are normally located near the load that they drive See the machine s Air Print for in depth information Note Labels on the solenoids identify loads they control Location of Valve Banks on the 965X FIGURE 4 39 Location of Valve Banks Cutter Head Valve Bank Chisels Left an...

Page 86: ...e to coupler interfaces located near the sections they control See your machine s schematic package for detailed wiring information Connections to Servo Drives The Servo Drives are located in the Main Electrical Panel The outputs connect to the servo motors of carious assemblies They may include the Head X Y and Z motors feed motors back section location X Y and Z motors For detailed wiring inform...

Page 87: ...t with the Template PLC and servo drivers They are highly accurate in movement and posi tion The motors are part of the calibration of the machine See the calibration chapter for axis direction FIGURE 4 41 Location of Servo Motors X Axis Servo Motor Z Axis Servo Motor Y Axis Servo Motor Chisel Cylinders Standard Router Cylinder CCW Router Cylinder Predrill Cylinder ...

Page 88: ...ye 0VDC is sent to the PLC As a result any of the photo detectors output equals 0VDC when a door is sensed Some detectors have an emitter and receiver built in one unit such as an in feed sensor where a door blocks the light and reflects back to the unit Some detectors have an emitter and receiver built in separate units such as the through beam sensor set at a distance from each other If an assem...

Page 89: ...e Typically the range should be 3 4 to 7 8 from the top of all eyes to the door FIGURE 4 42 Examples of Sensor Sensor Locations on Machine Sensors that are located on Frame and the Cutter Head the machine are identified in the illustra tions below and on the next page See the machine E Print for more information about the sen sors Frame Sensors FIGURE 4 43 Frame Sensor Locations The Limit Switch i...

Page 90: ...sors Figure 4 44 shows the locations of the sensors location on the Cutter Head In addition to crash sensors the cutter head homing sensor is also present FIGURE 4 44 Cutter Head Sensor Locations Homing Sensor Z Axis Crash Sensor Y Axis Crash Sensor X Axis Crash Sensor ...

Page 91: ...tching 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 Descriptio...

Page 92: ...of the Light Tower below for more information Note Most electrical problems are related to mechanical malfunction e g stuck motors jammed chain blocked photo sensors etc Note If a solenoid valve is suspected and not cleared in the air checks section see it can be electrically jumped to check operation 4 With the power off check for motor overloads by pressing each reset button usu ally at the bott...

Page 93: ... Red Machine Error Solid General Error 1 Flash EtherCat Device not Ready to Run 2 Flashes VFD Servo or Motor Error 3 Flashes 24 VDC Power Error Yellow External Error Solid General Error 1 Flash 3 Phase Voltage Error 2 Flashes Low Air Error Blue Operator Status Solid Waiting for Operator 1 Flash Reposition Door Green Machine is Operational Safety OFF Clear Safety Project not Running Red Safety PLC ...

Page 94: ...Description of the Light Tower 4 28 965X Service Manual ...

Page 95: ......

Page 96: ...partment Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL Phone and Fax In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email service kvalinc com http www kvalinc com ...

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