Kval 979-2 System Reference Manual Download Page 7

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979-2

If the Power Stops During Normal Operation

............................................60

Troubleshooting with the Status Light Panel ...............................................61

Adjusting Limit Switches ........................................................................64

Troubleshooting Photo Detectors .......................................................................65
Getting Help from Kval

.....................................................................................66

Product Return Procedure ............................................................................66

Touch Screen Troubleshooting

..........................................................................67

Maintenance Screen .....................................................................................67
Machine Status

........................................................................................68

.....................................................................................................................68

Sequence does not complete

.......................................................................69

Start Sequence (Feed)

.................................................................................70

Saws do not extend

.....................................................................................71

Saws do not start

.........................................................................................72

Heads do not adjust .....................................................................................73
PLC Input-Bit Status ...................................................................................74
PLC Output-Bit Status

................................................................................75

.....................................................................................................................75

PLC M-Bit Status .........................................................................................76
GALIL IO Status .........................................................................................77
Kerf Saw Sequence (optional)

....................................................................78

Technical Support

........................................................................................79

Servo Trouble Shooting

...............................................................................80

Limit - Switch Timing

.................................................................................81

General process description: .....................................................................81

979-2 X Axis Limit Switch Timing

.............................................................82

Set Minimum Cut .........................................................................................83

Part Locations

....................................................................................................85

Warranty .............................................................................................................91

Summary of Contents for 979-2

Page 1: ...979 2 Innovation Quality Honesty 979 2 Miter Trim Saw System Reference Published 4 24 07 ...

Page 2: ...979 2 ...

Page 3: ... products contact the Customer Support Department http www kvalinc com customer_service html lists all the representatives including email addresses and phone numbers Mailing address Customer Support Department Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 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 fa...

Page 4: ...b 979 2 ...

Page 5: ... Check Controls 6 Remove Locks 6 Execute Visual Checks 6 979 2 Guard Placements and Purpose 8 Initial Set up 9 Trubolt Wedge Anchor 10 INSTALLATION INSTRUCTIONS 10 Electrical Connections Overview 11 CHAPTER 2 Operation 13 Machine Tour 15 Quick Start 17 Turning the 979 2 On and Off 19 Powering Up the 979 2 19 Powering up the system includes 19 To Power Up the 979 2 19 Powering Down the 979 2 19 To ...

Page 6: ...ication Requirements 42 Linear Bearings 42 Flange Bearing and Pillow Blocks 42 Approved Lubrication Products for Lubricators 42 Gear Motor Lubrication Requirements 42 Ball Screws 42 Adjusting the Air Line Lubricator not available on all machines 43 Grease Points 44 Main Frame Bottom View 44 Fixed Head 45 Movable Head 46 Cut Depth Set up 47 Adjusting the Saw Height 47 Feed Cylinder replacement and ...

Page 7: ...e 69 Start Sequence Feed 70 Saws do not extend 71 Saws do not start 72 Heads do not adjust 73 PLC Input Bit Status 74 PLC Output Bit Status 75 75 PLC M Bit Status 76 GALIL IO Status 77 Kerf Saw Sequence optional 78 Technical Support 79 Servo Trouble Shooting 80 Limit Switch Timing 81 General process description 81 979 2 X Axis Limit Switch Timing 82 Set Minimum Cut 83 Part Locations 85 General Top...

Page 8: ...f 979 2 ...

Page 9: ... finished casing Air consumption is just 8 CFM The hopper feed system accommodates material up to 4 inches wide and from 12 inches to 100 inches in length The precision parallel feed system guarantees parallel indexing of work pieces under neath saw blades Saw motors are three phase 3HP Saws pivot between either 0 or 90 degree positions The CNC index system will automatically com pensate for cut l...

Page 10: ...Introduction 2 979 2 ...

Page 11: ...In addition to this equip ment you must install an approved disconnect for the electri cal power supplying this machine When opening the cabinet you must first turn off the discon nect switch When the cabinet door is open there is still power on the top side of the disconnect switch All maintenance and repairs to electrical circuitry should only be performed by a qualified electrician Before Condu...

Page 12: ...FF 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 example below 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 Other Hazard Control Action If...

Page 13: ... by the person s who placed them and the machine can be re energized 9 The tags must be destroyed and the locks and keys returned to the lockout center Lockout and Tagout Guidelines Place a tag on all padlocks On the tags include your name and date These locks are only to be removed by the person on the tag If more than one person is working on the machine then each additional person places a lock...

Page 14: ...matically when energy is restored Remove Locks Each person must remove his or her own lock and tag This will ensure operators are in a safe place when the equipment is started Execute Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the person nel alarm before starting the equipment If your operation is more complex having many pieces of ...

Page 15: ...er lock out tag out procedures work because you are the only one with the key to your lock Proper lock out tag out can save lives limbs and money Help make your work environment safe for yourself and your fellow employees Make sure you follow the P R OP E R lock out tag out proce dures and that those around you do also YOUR LIFE MAY DEPEND ON IT ...

Page 16: ...h belt guard located on the flange of the guard near the saw assem bly springs Removal of the belt guard requires the operator to first remove the saw assembly guard 3 Feed Assembly Guard Located on the inboard sides of both saw carriage feed dog assemblies The feed assembly guard pro tects the operator from getting hands caught inside the moving parts of the feed assembly The guard provides prote...

Page 17: ...kids there is a chance that the machine could drop suddenly which could damage the machine or injure people near the machine 3 Remove all painted set collars from the shafts Almost every shaft on the machine has set collars to secure the moveable assembly mounted to the shafts 4 Remove any tape securing the various buttons switches and knobs Level your Kval machine by put ting metal shims undernea...

Page 18: ...ne needs to be moved remove the Red Head nut and pound the bolt flush with the floor surface 2 Assemble anchor with nut and washer so that the top of the nut is flush with the top of the anchor Drive anchor through material to be fastened so that nut and washer are flush with surface material 3 Expand anchor by tightening nut 3 to 5 turns torque requirement 55 ft lbs for a inch Red Head Trubolt ...

Page 19: ...trical power is connected to the disconnect located in the main electrical panel NOTE The main electrical panel contains the PLC The 979 2 requires three phase power Refer to the plant layout diagram or the brass information plate to determine the voltage required If the 979 2 is equipped with kerf saws an additional 120 volt source is required Current Requirements 220 volts 20 amps 460 volts 10 a...

Page 20: ...12 979 2 ...

Page 21: ...979 2 13 CHAPTER 2 Operation The following chapters explain normal operation of the 979 2 ...

Page 22: ...Operation 14 979 2 ...

Page 23: ...Machine Tour 979 2 15 Machine Tour Left or Fixed Head Right or Movable Head Control Transformer Button Start Machine Button E Stop Button E Stop Pull Cord E Stop Button Optional ...

Page 24: ...16 979 2 ...

Page 25: ...alibration See Calibration on page 37 5 Modify the preset for the desired quantity 6 Load the hopper and start production by press ing the Start Sequence foot pedal Pick one R 1 R 3 R 12 R 11 R 10 R 9 R 8 R 7 R 6 R 5 R 4 R 2 98 250 78 250 96 250 80 250 96 250 78 250 96 500 98 000 78 750 81 000 98 000 96 500 Pick one R 1 R 3 R 12 R 11 R 10 R 9 R 8 R 7 R 6 R 5 R 4 R 2 98 250 Right 4 50 78 250 78 250...

Page 26: ...18 979 2 ...

Page 27: ...disconnect on both electrical cabinets are turned to the ON position 3 Pull out the CONTROL TRANSFORMER switch It should light up 4 Push the START button 5 All lights on the status light panel on the electrical box should be illuminated 6 The 979 2 will now go through the homing routine The O K to Move popup will appear The OK to Move button must be held when the movable cutting head is moving The...

Page 28: ...ng head One foot switch One cable pull switch the cable running around the entire base of the machine optional The E Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment When an E Stop switch is activated power to the machine is killed NOTE The machine responds in the same way if you press the STOP button on the operator s station To Resume N...

Page 29: ...nt modes Left Puts the Left Head at 0º and the Right Head at 45º Head Puts the Left Head at 45º and the Right Head at 45º Right Puts the Left Head at 45º and the Right Head at 0º Stop Puts the Left Head at 0º and the Right Head at 0º Left Head Right Head ...

Page 30: ... same distance as the stock width For 0 degrees set the end stop distance for 0 inches 4 Set the front edge clamp distance to the same as the stock width 5 Set the jamb clamp width air valves For stock less than 3 inches the valve must be slid toward the input side of the machine For stock greater than 3 inches the valve must be slid toward the out feed side of the machine 6 On the Touch Screen pr...

Page 31: ... than 3 1 2 Slide forward for stock width greater than 3 1 2 Less than 3 1 2 Greater than 3 1 2 Rear Hopper Stop Adjust rear hopper stop to set hopper width to 1 8 wider than stock Front hopper stop Front hopper adjustment bolts End stop distance indicator Set to stock width distance Adjust front hopper stop height to clear stock by app 1 8 ...

Page 32: ...m the preset field 3 Note For Right Jamb and Left Jamb modes there are 12 quick access presets available For Head and Stop modes there are 24 quick access presets available To access presets 13 to 24 in Head and Stop modes press Next Page Note See Preset Screen on page 31 for a detailed description of this screen R 1 R 3 R 12 R 11 R 10 R 9 R 8 R 7 R 6 R 5 R 4 R 2 98 250 Right 4 50 78 250 78 250 78...

Page 33: ...nter the desired preset 3 Press Download Preset 4 The O K to Move popup will appear Hold the O K to move button until the head is in position 5 The 979 is now ready for work Note See Length Preset Screens on page 32 for a detailed description of this screen Keypad Display Keypad Decimal Fraction Modify Quantity Previous Menu Entered Value 27 27 Quantity 50 15 Download Preset ...

Page 34: ...esired length and preset number 6 Press Store Program 7 To store more presets go back to step 26 8 Press Previous Menu until you reach the Main Run Screen 9 On the Main Run screen press Refresh Text to make the new presets visible 10 Turn the Set Up key switch to Off Note See Length Only Screen on page 34 for a detailed description of this screen Keypad Display Keypad New Length Store Program New ...

Page 35: ...h 3 Press Download Length 4 The O K to Move popup will appear Hold the O K to move button until the head is in position 5 The 979 is now ready for work Note See Length Preset Screens on page 32 for a detailed description of this screen Keypad Display Keypad Decimal Fraction Modify Quantity Previous Menu Entered Value Current Mode Current Preset 27 27 Quantity 50 HEAD 15 Download Length ...

Page 36: ...28 979 2 ...

Page 37: ...ime the cut length is changed the OK to Move popup appears The OK to Move button must be pressed during the time the movable head is moving This safety feature ensures the operator will be in a safe position at the touchscreen and not near the moving heads If Abort Move is pressed the dis play returns to the previous screen HOMING 82 013 Current Cut Length ...

Page 38: ...mb OFF For stock less than 3 inches wide ON For stock wider than 3 inches wide NOTE Jamb width change also requires a mechanical adjustment See Mechanical Set up on page 22 Refresh Text Updates the text for the current display Machine Data Moves to the Machine Data screen See Machine Data on page 35 Clamp Setup Turns off the saws to allow the user to safely set up the clamps page 22 Controller Sta...

Page 39: ...to allow the user to safely set up the clamps page 22 Current Preset Displays the currently selected mode and preset Next Page Moves to the Keypad Length Preset screen See page 32 Previous Menu Moves to the Main Run screen See Run Screen on page 30 Preset Quantity Displays the quantity saved in the currently selected preset Present Length Fractional Displays the length saved in the currently selec...

Page 40: ...for each mode Head Left Right Stop Quantity Displays the current quantity Previous Menu Returns to the previously displayed screen Modify Quantity Used to modify the saved quantity by calling the Keypad Modify screen page 33 Fraction Used to call the Key Fractional screen page 33 for entering numerical data in a frac tional format Decimal Used to enter a decimal point into a keypad entered numeric...

Page 41: ...shown in thirty seconds of an inch For example if 1 4 is pressed 08 32 will be displayed When the correct value has been entered press previous menu to return to the previous screen Keypad Quantity Screen This screen is used to change the number of parts to be processed Enter the desired number using the keypad then press Close Menu to return to the previous screen 08 32 Keypad ...

Page 42: ...the Key Switch labeled Set Up located on the main electrical box must be in the ON position Previous Menu Returns to the previously displayed screen Fraction Used to call the Key Fractional screen page 33 for entering a length in fractional for mat Decimal Used to enter a decimal point into a keypad entered length Keypad Used to enter a length Keypad Display Displays the length entered from the ke...

Page 43: ...hine Total Total number of boards run through the machine Daily Total Number of boards run throught the machine since Reset Daily was pressed Reset Daily Sets the Daily Total to 0 Previous Menu Returns to the previously displayed menu Previous Menu Reset Daily Daily Total Machine Total ...

Page 44: ...he Run screen Run Screen on page 30 or the Preset screen Preset Screen on page 31 turns off the saws to allow for safe clamp set up see Mechanical Set up on page 22 After the clamps are set use the screens shown above to re start the saws Ready to run No cut loaded ...

Page 45: ...appropriate calibration type Current cut angles This calibration affects all presets with the currently selected cutting angles In the following example the calibration would affect all 45 degree and 0 degree cuts Use this calibra tion if a test cut is incorrect during standard production Global This calibration affects all presets Use this calibration after mechanical changes to the machine such ...

Page 46: ...to app 2 inches shorter A note on calibration A 979 2 properly calibrated and mechanically set up will accurately make cuts within 1 1000 tolerance Cut length accuracy is more dependant on material quality than the 979 2 On longer stock where bowing is an issue use the center support to reduce this problem ...

Page 47: ...979 2 39 CHAPTER 4 Maintenance This chapter describes how to maintain the 979 2 system This chapter contains the following informa tion Maintenance schedule page 40 Lubrication requirements page 42 ...

Page 48: ...check to ensure that all fastening nuts are snug CAUTION Fastening nuts as well as eyes are plastic and threads can strip easily Check the air pressure to make sure it is set at 100 psi Refill lubricator with an ISO 32 standard hydraulic oil use KVAL part SYSLUBEG Weekly Check the machine for smooth motion through a complete door cycle Clean linear bearings and chrome shaft with a clean dry cloth ...

Page 49: ... any worn or broken parts May and December Checkups Wash filter and lubricator bowls with soapy water Grease all bearings and tighten all bolts see grease locations on illustrations Access to some grease fittings is difficult and will require a special needle point grease tip supplied with your system Clean and lubricate all slides and cylinder rods with dry silicone spray Tighten all bolts Lift u...

Page 50: ...w Blocks Use Dura Lith grease 1 gram every 60 days Approved Lubrication Products for Lubricators Chevron AW Hydraulic Oil 32 or KVAL P N SYSLUBG or G C lubricants light AW R O or Mobile DTE 24 or Shell Tellus32 or Gulf Harmony 32 Gear Motor Lubrication Requirements Oil change is recommended after 2000 hours or six months of operation Use AGMA 8 gear lube or MOBILUBE HD 80 W 90 or equivalent Ball S...

Page 51: ...at is energized and dis connect 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 pro cedure for the back section and other trouble areas Check the lines every week to two weeks NOTE The Lubricator is not installed on all machines Sight glass Drop will fo...

Page 52: ...Maintenance 44 979 2 Grease Points Main Frame Bottom View Bottom View ...

Page 53: ...Lubrication Requirements 979 2 45 Fixed Head ...

Page 54: ...Maintenance 46 979 2 Movable Head Bottom View ...

Page 55: ...Remove the saw carriage guard 3 Remove the saw travel limit switch actuator mounting plate 4 Loosen the two bolts securing the saw mounting plate 5 Raise or lower the saw position as necessary 6 Re tighten the saw mounting plate bolts 7 Re install the saw travel limit switch actuator mounting plate 8 Adjust the saw travel limit switch actuator adjusting screw if necessary in or out until the saw t...

Page 56: ...48 979 2 ...

Page 57: ...Cut Depth Set up 979 2 49 ...

Page 58: ...50 979 2 ...

Page 59: ...Cut Depth Set up 979 2 51 ...

Page 60: ...52 979 2 ...

Page 61: ...sed air 1 Remove the inside covers l 2 Manually Pull both movable and fixed head dog plates against the Feed Forward stops 3 Replace the Feed Cylinder Feed Cylinder 4 Adjust the new Feed Cylinder placement to insure Feed Dog Plate has smooth travel for the full range of motion 5 Tighten the Feed Cylinder lock nuts Feed Forward Stop Feed Cylinder Feed Dog Plate Feed Reverse Stop ...

Page 62: ...against the Fixed Head Dog plate adjust the forward feed stops so both the fixed head middle feed dog and movable head feed dog and the alignment mark all line up Movable Head Feed Middle Dog Fixed Head Fixed Head T Square Middle Feed Dog Plate Movable Head Plate Fixed Head Fixed Head Forward Feed Stop Movable Head Forward Feed Stop Fixed Head Dog Plate Movable Head Dog Plate Alignment Mark ...

Page 63: ... both movable and fixed head dog plates agents the Feed Reverse stops 8 Adjust the Feed Reverse stop for a gap of 8 15 16 between the forward edge of both Feed Dog Plates and the Feed Forward Stop 9 Reinstall the inside covers Feed Forward Stop Feed Dog Plate Feed Reverse Stop 8 15 16 ...

Page 64: ...56 979 2 ...

Page 65: ...979 2 57 CHAPTER 5 Troubleshooting ...

Page 66: ...s 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 exhausting through the solenoid valve It maybe is necessary to...

Page 67: ...de If the solenoid has a manual override 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 Adjusting Cylinder Retraction Speed ...

Page 68: ...urn the panel disconnect switch in the off position open the electrical panel door 5 Observe the disconnect switches Look for loose or broken wires at the disconnect then at all of the components 6 Check for continuity of all fuses with an OHM meter 7 Check motor overloads by pressing each white button usually at the bottom of the panel in SEQUENCE If one is tripped there will be a slight resistan...

Page 69: ...e Operator s Station below the work surface area It has six lights that are all illuminated when the system is in proper working order If one or more lights are OFF follow the process below to ascertain the cause NOTE Be sure to proceed down the table starting with the CONTROL POWER light CONTROL POWER OVERLOAD RELAY E STOP STOP START 24VDC ...

Page 70: ...are near the Rear Access Gate and near the Tool Changer Access Gate For Single E Stop button machines Check for 110 VAC between 2 and 4 If no voltage check to see if the E Stop button is pulled out If the E Stop button is pulled out and E Stop light is OFF check the wiring If no fault is found in the wiring turn off the DL NCB main power and check for conti nuity across the pulled out E Stop switc...

Page 71: ...ween DC and DC for 24VDC If no DC voltage disconnect the Brown Red and Blue Black wires from 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 If there is 24VDC Reconnect the Brown Red and Blue Black wires to the 24VDC power s...

Page 72: ... arm s resting position to the position at which the switch actuates with a click is either 5 or 20 degrees The DL NCB has five limit switches that have 5 degrees of pre travel 3 on the X axis and 2 on the Y axis and two switches that have 20 degrees of pre travel on the Cutter head If the arm is moved to the full extent of its travel and you do not hear the limit switch click the switch needs to ...

Page 73: ...n sends 0VDC to the PLC If the beam is broken the detector sends 24VDC to the PLC 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 The Photo Eye then sends 24VDC to PLC If no object is sensed the Photo Eye sends a 0VDC to the PLC If the photo detector is dirty it will ...

Page 74: ...turn the unit have someone from your organization with a technical understanding of the 979 2 system and its application include answers to the following questions What is the extent of the failure reason for return What are the relevant error messages or error codes How long did it operate Did any other items fail at the same time What was happening when the unit failed e g installing the unit cy...

Page 75: ...ENCE DOES NOT COMPLETE X See page 69 W START SEQUENCE FEED X See page 70 W SAWS DO NOT EXTEND X See page 71 W PLC INPUT BIT STATUS X See page 74 W GALIL I O STATUS X See page 77 W SAWS DO NOT START X See page 72 W PLC OUTPUT BIT STATUS X See page 75 W KERF SAW SEQUENCE X See page 78 W HEADS DO NOT ADJUST X See page 73 W PLC M BIT STATUS X See page 76 W TECH SUPPORT X See page 79 W CALIBRATION X Se...

Page 76: ...ft Extend M61 Internal PLC register requires PC to PLC interface and WindLDR program Right Cyl Ext Off Q 35 Cylinder See Right or Movable Head on page 86 for location Left Cyl Ext Off Q 34 Cylinder See Left or Fixed Head on page 87 for location Left 0 Deg M 334 Internal PLC register requires PC to PLC interface and WindLDR program LS Left 0 Deg Pos I 01 Limit switch See Heads Bottom View on page 8...

Page 77: ...itch See Left or Fixed Head on page 87 for location Right Cut Started M 36 Internal PLC register requires PC to PLC interface and WindLDR program LS Right Saw UP I 07 Limit switch See Right or Movable Head on page 86 for location LS Feed retracted I 10 Limit switch See Heads Bottom View on page 88 for location Saw Motors Retracted M 20 Internal PLC register requires PC to PLC interface and WindLDR...

Page 78: ...iter Stop OFF M 333 Internal PLC register requires PC to PLC interface and WindLDR program PE Board Straight 1 I 12 Photo Eye See Left or Fixed Head on page 87 for location PE Board Straight 2 I 13 Photo Eye See Right or Movable Head on page 86 for location Straight T 11 Internal PLC timer requires PC to PLC interface and WindLDR program ...

Page 79: ...tart Saws T 09 Internal PLC timer requires PC to PLC interface and WindLDR program Start Saw Cyl Extended M 33 Internal PLC register requires PC to PLC interface and WindLDR program Left Cut Started M 35 Internal PLC register requires PC to PLC interface and WindLDR program Left Cut Started M 34 Internal PLC register requires PC to PLC interface and WindLDR program Right Cut Started M 36 Internal ...

Page 80: ... 07 Limit switch See Right or Movable Head on page 86 for location Left Kerf Retracted I 14 Underneath left head at retracted end of Kerf saw travel no picture available Right Kerf Retracted I 15 Underneath right head at retracted end of Kerf saw travel no picture available Setup Mode M 290 Internal PLC register requires PC to PLC interface and WindLDR program ...

Page 81: ... Not Up Pos I 07 Limit switch See Right or Movable Head on page 86 for location Left Kerf Retracted I 14 Underneath left head at retracted end of Kerf saw travel no picture available Right Kerf Retracted I 15 Underneath right head at retracted end of Kerf saw travel no picture available OK to Move Heads M 290 Internal PLC register requires PC to PLC interface and WindLDR program ...

Page 82: ...t switch See Heads Bottom View on page 88 for location I 02 Right Head 45 DEG Limit switch See Heads Bottom View on page 88 for location I 03 Not used I 04 Start Sequence Foot Switch no picture available I 05 Not used I06 Left Saw UP Limit switch See Left or Fixed Head on page 87 for location ...

Page 83: ...available Q 01 Right Kerf Saw Limit switch See Heads Bottom View on page 88 for location Q 03 Not used Q 04 Eye Blow Off Blow off for photo eyes on both left and right heads See page 87 and page 86 Q 05 Clamp Clamps on both left and right heads No picture available Q 6 Feed Cylinder Cylinder to power feed an both left and right heads No picture available ...

Page 84: ...76 979 2 PLC M Bit Status All M Bits are internal PLC registers Viewing requires PC to PLC interface and WindLDR program ...

Page 85: ... 1 Servo Request to move PLC I 41 GALIL 0 02 GALIL OUT 2 45 45 PLC I 42 GALIL 0 03 GALIL OUT 3 0 0 PLC I 43 GALIL 0 04 GALIL OUT 4 45 0 PLC I 44 GALIL 0 05 GALIL OUT 5 0 45 PLC I 45 GALIL 0 06 GALIL OUT 6 In Position PLC I 46 GALIL 0 07 GALIL OUT 7 Quant 0 In Position PLC I 47 GALIL 0 08 GALIL OUT 8 Homed ...

Page 86: ...ailable Cylinder Down Q 07 Cylinder to move left Kerf saw No picture available Right 45 DEG I 02 Limit switch See Right or Movable Head on page 86 for location Motor Start Q 01 Right Kerf saw motor located under left head No picture available Cylinder Down Q 010 Cylinder to move right Kerf saw No picture available Saw Motors Retracted M 20 Internal PLC register requires PC to PLC interface and Win...

Page 87: ...Touch Screen Troubleshooting 979 2 79 Technical Support Contact information ...

Page 88: ...otor Thread and I O Error Log buttons call screens that display the present motion control system status This information may be required by a service technician during troubleshooting Limit Switch Timing See page 81 SET Minimum cut See page 83 ...

Page 89: ...witch activator bolt needs adjustment If adjustment is necessary put wrenches on both the limit switch activator bolt and the limit switch lock bolt then loosen the lock bolt The limit switch activator bolt is now free for adjust ment Adjustment should be made in small increments best practice being two or three bolt flats at a time If the motor rotation is less the 4 turn the limit switch activat...

Page 90: ...top at the far end of the machine It will them move slowly toward the fixed head and stop 4 If Passed appears at the top of the Servo trouble shooting the process is complete If Failed appears at the top of the servo trouble shooting screen a second message will appear giving instructions on how to adjust the home limit switch activation bolt Follow the instructions then go back to step 2 See the ...

Page 91: ...n press Servo Troubleshooting 2 Press Set Minimum Cut 3 The O K to move screen will appear Press the O K to move button to allow the machine to run the Set Mini mum Cut routine The movable head will travel toward the fixed head and stop The minimum cut distances will appear at the top of the servo trouble shooting screen ...

Page 92: ...84 979 2 ...

Page 93: ...Part Locations 979 2 85 Part Locations General Top View Control Transformer Button Left or Fixed Head Right or Movable Head Start Machine Button E Stop Button E Stop Button ...

Page 94: ...etracted LS 7 I07 Limit Switch Right Saw Extended LS 35 I35 SV 25 Cylinder Extended Q35 Port B Retracted Q35 Port A Control Valve Extend Right Saw SV 35 Q35 Right Saw Extended Retracting the Right Saw Extend cylinder will cause the Right Saw to drop Extending this cylinder will cause the Right Saw to rise Machine Sensor locations Touch Screen PLC Output label Touch Screen Label PLC port ...

Page 95: ... Port B Retracted Q34 Port A Control Valve Extend Left Saw SV 34 Q34 Retracting the Left Saw Extend cylinder will cause the Left Saw to drop Extending this cylinder will cause the Left Saw to rise Motor MTR1 Left Saw MC 2 Q2 Photo Eye Board 1 Straight PE 12 I12 Blow Off Q4 Key Description PLC Output label Touch Screen Label PLC port Machine Sensor locations Touch Screen ...

Page 96: ... Left Saw 45º I01 Limit Switch Feed Retracted I10 Limit Switch Feed Forward I11 Bottom View Left Head Right Head Cylinder Left Saw 45º Extend Q32 Retract Q33 Limit Switch Left Saw 45º I02 Key Description PLC Output label Touch Screen Label PLC port Machine Sensor locations Touch Screen ...

Page 97: ...Crash Main Valve Bank LS 50 I50 Limit Switch Crash LS 51 I51 Limit Switch Home LS 52 I52 Port A Port A Blow Off Clamp Feed Cylinder counter Port B Port B Left Saw 0º Q31 Right Saw 45º Q32 Right Saw 0º Q33 Left Saw 45º Q30 Q4 Q5 Q6 Machine Sensor locations Touch Screen ...

Page 98: ...90 979 2 ...

Page 99: ...as determined by material safety data information and maintenance recommendations in this owners manual Parts returned under warranty will be inspected by Kval to determine whether that part qualifies for repair or replacement as specified in this warranty KVAL Inc is not responsible for costs associated with downtime lost orders damage to customer s product or workpieces or other costs not specif...

Page 100: ...92 979 2 ...

Page 101: ...re 4 P photo detectors troubleshooting 65 power disconnect switches 4 lock out procedure 4 troubleshooting 60 product return procedure 66 proximity sensors See photo detectors R return material authorization RMA 66 returning the product to Kval 66 S safety cage guidelines for entering 3 safety guidelines 3 sensors See photo detectors shutoff valve air 43 T tag out guidelines 5 technical support 66...

Page 102: ...94 979 2 ...

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