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KVAL 990-FX Operation/Service Manual

Proprietary Notice

This Manual is confidential and contains proprietary information and intellectual
property of KVAL Inc., and i s to be used solely by Customer as an operating manual
for KVAL Inc. machines. Neither this Manual nor any of the information contained
herein may be reproduced or disclosed under any circumstances without the express
written permission of KVAL Inc. For authorization to copy this information, please
call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the
U.S. and Canada, call (707) 762-7367.
Manual Part Number:

093_OPSRV_990FX_V5 (SN 17-93-28)

The 990-FX Door Hanging System is a trademark of Kval Incorporated.
Copyright 2014 Kval Incorporated. All rights reserved.

Beckhoff

®

, TwinCAT 2

®

, and EtherCat

®

are registered trademarks and are licensed

by Beckhoff Automation GmbH

Windows 7

®

is a registered trademark of Microsoft Corporation.

All other products are trademarks or registered trademarks of their respective holders,
all rights reserved. Reference to these products is not intended to imply affiliation with
or sponsorship of Kval Incorporated.

Contacting KVAL

Customer Service:

For further information about this manual or other Kval Incorpo-

rated products, contact the Customer Support Department

• 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 fax (707) 762-0485

• Business hours:

Technical Support:

6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday

Parts & Service Sales:

6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday

6:30 AM to 1:30 PM Pacific Standard Time, Friday

(Other sales related inquiries: http://www.kvalinc.com)

• Email: [email protected]

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Summary of Contents for 990FX

Page 1: ...Innovation Quality Honesty Operation and Service Manual Published 03 13 2018 990 FX Pre Hanging Door System 990 FX Operation and Service Manual ...

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

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 990 FX Operation Service Manual ...

Page 5: ...agout Procedure 1 10 Pre Steps Before Lockout Tagout 1 10 Lockout Tagout Power 1 10 Lockout Tagout Air Supply 1 11 Start Maintenance 1 11 Post Maintenance Steps 1 11 Zero Energy to Start Up 1 12 Getting Help from KVAL 1 14 On Line Help 1 14 Product Return Procedure 1 14 How to Download the Service Application 1 16 Download Application 1 16 Safety Sign Off Sheet 1 19 A Note to the Operator 1 19 Cha...

Page 6: ...on 2 20 About the Out Feed 2 21 About the Electrical Panels 2 22 Main Electrical Panel 2 22 High Frequency Panels 2 23 About the Nodes 2 23 Graphical Sample of Node Connections 2 24 Options 2 25 Option BC Ball Catch 2 25 Option N Dust Blow off System 2 25 8 0 Foot Door for FX 2 26 About the Shift Function 2 26 Option H Securing Split Jambs 2 27 Option Z Screw Changing Hoppers 2 28 Description of t...

Page 7: ...tion 2 49 Diagnostic Screen 2 52 Glossary of Common Terms 2 54 Chapter 3 System IT Administration System IT Administration 3 2 About the Machine Computer 3 2 Connections on the PLC 3 2 Network Diagram 3 3 Backing up the Computer 3 3 About Remote Connection to KVAL Service 3 4 Chapter 4 Maintenance of the 990 FX Maintenance Schedule 4 2 300 Cycle Maintenance Steps 4 4 Clean Clean Clean 4 4 600 Cycl...

Page 8: ... Inspect Nuts and Bolts 4 13 Check Door Feeding Transition 4 13 Electrical 4 13 Computer Backup 4 13 Wash Filter and Lubricator Bowls 4 13 Tool Changing Schedule 4 14 Maintenance NO GOES 4 16 Lubrication Schedule 4 17 Typical Lucubration Kit 4 17 Lubrication Schedule 4 18 Typical Lucubration Kit 4 18 Lubrication Requirements 4 19 Pillow Block Bearing Housings 4 19 Flange Bearing Housings 4 20 Ball...

Page 9: ... the Sub Systems 5 5 About a Typical Contactor Control 5 7 About Contactor Troubleshooting 5 8 About Typical VFD Motor Drive Control 5 9 About the VFD 5 10 About VFD Troubleshooting 5 11 About a Typical Pneumatic Circuit 5 12 Typical Pneumatic Assembly 5 13 About the Coil Solenoid 5 13 About Cylinder Operation 5 14 How the Pneumatic System Works 5 14 Important Notice about Adjusting Cylinder Speed...

Page 10: ...is and Y Axis Front Section Sensors 5 28 X Axis Sensors Front Section 5 29 Network System Overview 5 30 Connections to Servo Drives 5 30 High Frequency Panel Node Connections 5 31 Frame Screw Driver and Back Section Node Locations 5 32 Frame Node Connections 5 33 Screw Driver Nodes 1 3 Opt 4 5 33 Back Section Node 5 33 ...

Page 11: ...X This section includes a general description and a table of available options page 1 2 Safety IMPORTANT safety information is described in this section page 1 4 Zero Energy to Start Up Procedure to power up your machine for the first time page 1 12 Getting Help from KVAL This section describes the method to contact the KVAL service center for help The section includes how to get information from ...

Page 12: ... on both door and jamb Machine also includes automatic door width adjustment to accommodate mixed stacks and automatic door positioning with a two speed feed belt system Operation Door is automatically positioned while the operator loads and clamps the hinge jamb Routing and boring occur while the operator places hinges into the nests of the three hinge appli cators Pressing the In button fastens ...

Page 13: ...f a door that can be machined to 18 Option I Reverse Feed Facing the hinge routers the normal feed direction is left to right Option IL Door Hand Indicator Light Light will be mounted on the out feed end of the 990 FX that can be seen by the 700 C Assembly Table operator The light will be on when the door in the 990 FX is being machined as a right hand door and off for a left hand door Option N Du...

Page 14: ...owing Chapter Title Description Chapter 1 Introduction Descriptions of Machine Line and Safety Information Chapter 2 Operation Interface Descriptions of how to power machine line and operator interface user screens Includes Calibration Chapter 3 IT System Description IT System Chapter 4 Maintenance Maintenance steps for the machine line Chapter 5 Trouble Shooting Troubleshooting tips and theory of...

Page 15: ...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 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 machin...

Page 16: ... down Never perform any maintenance unless machine is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Bef...

Page 17: ...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 out or lock o...

Page 18: ...ident If you believe any part or operation of this machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed 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 ope...

Page 19: ...ock and 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...

Page 20: ... air supply 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 p...

Page 21: ...etc are completely 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...

Page 22: ...ally 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 starting the equipment If your operation is more complex your company s c...

Page 23: ... the key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect ...

Page 24: ...riday 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 Product Return Procedure If you ve contacted KVAL for help and it is determined that a return is necessary use the proce dure below to return the machine or part Note Non Warranty returns are sub...

Page 25: ...ere 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 documented reason for return available 4 Send the merchandise back to KVAL Make sure the item s you...

Page 26: ...c com 2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Goog...

Page 27: ...l Program is ready to allow technicians to access machine computer Your Name 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 Supp...

Page 28: ...How to Download the Service Application KVAL 990 FX Operation Service Manual 1 18 Page Intentionally Left Blank ...

Page 29: ... follow 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 elec...

Page 30: ...Safety Sign Off Sheet KVAL 990 FX Operation Service Manual 1 20 ...

Page 31: ...ame Summary Page About the Machine Line General Information About The Machine Line page 2 2 Summary of Machine Controls Description Of The Machine Line Controls page 2 4 Safety Controls A Summary Of The Safety Controls On The Machine Line page 2 8 Tours of the Machines A Summary Of The Machine Assemblies page 2 11 Powering the Machine Line Instructions To Powering The Machine Line page 2 33 Descri...

Page 32: ... or rotatory configuration The ON 3 Automatically lifts a door from a stack in the staging area The door is placed onto the powered roller The door is fed into the 990 FX automatically or with a call door function After the door is fed into the 990 FX the action is repeated For a detailed description of the 700 C see the ON 3 Operation Service Manual The 700 C IA strike jamb and Header are placed ...

Page 33: ...of the Hoppers are customer preference Operator s Station Six Shooter 4 Option Six Shooter 2 Six Shooter 3 Six Shooter 1 Carriage Head 4 Option Carriage Head 3 Carriage Head 2 Carriage Head 1 Electrical Panel 1 Out Feed Front Section Back Section In Feed Path of Hinge Screw through tubes Air Tank Lock Bore Assembly Light Curtain Transmitte Light Curtain Receiver Electrical Panel 2 ...

Page 34: ...un predetermined parameters on doors Manually control the door path and process through the line Machine diagnostics are included as well as internet support and connectivity for remote support via our Service Sup port Main Control Panel Power Up and Power Down machines Start and stop the door pro cess See Tour of the Machine on page 2 11 Main Control Panel Power Up and Power Down machines Start a...

Page 35: ...rameters such a presets and cal ibrations Note Locked out parameters may vary due to customer preference Start Machine Button Wakes up the machine similar to a boot up Stop Machine Button Puts the machine to sleep Control Transformer Energize and De Energize the machines Lock Lock out access to Adjust ment E Stop push to shut down machine in an emergency situa tion To allow the operator to make ch...

Page 36: ...d and hands are safely out of the way Note Be prepared for the front section routers to move into position and begin routing as well as the back section routers lock bore and bolt drill The Six Shooter heads will also begin to move into position Door Auto RH LH Press for Auto Run or to receive either a left hand or right hand incoming door When in Auto Door mode the 990 FX receives information abo...

Page 37: ...al Hinges Loaded Button Light Curtain Status Light The 990 FX has Light Curtain Controls at the front of the machine Hinges Loaded Step out of the Safety Light Curtain and press this button after hinges are loaded on to the Hinge Applicators The Light Curtain will be activated ...

Page 38: ...d Stacker 990 FX Light Curtain The Safety Light Curtain provides safety for personnel who enter the defined area when the machine is active If any part of an operator s body is detected in the defined area the machine stops the operation The machine must be reset from the operators station to continue machining The Safety Light Curtain is composed of an EZ Screen emitter and receiver The emitter h...

Page 39: ... an E Stop is activated use the following procedure to recover after the cause of the emergency stop is resolved Status Indicator and Hinges Loaded Reset Breaking of any beam stops the machine Machine in operation Emitter Receiver 1 1 Push the START MACHINE button on the operator s station 2 3Press the Hinge Loaded Button 3 Home the Machine 2 ...

Page 40: ...ter assemblies The brakes will lock the six shooter in place avoiding a crash to the head The brakes are controlled by a lack of air pressure and will lock when the air pressure drops below a reference level Brakes are located on each side of the six shooter assemblies Bypass valve will bypass air causing the brakes to lock ...

Page 41: ... 2 3 Key Assemblies on the In Feed Section Lock Back Section Faceplate routing and boring for lock and bolt In Feed System Door is delivered from previous machine and fed into 990 FX for process ing Hydraulic Tanks for Six Shooters Supplies hydraulic pressure to operate Six Shooter Six Shooters Auto drop down to apply hinges and secure them with screws delivered from Hopper Six Shooter Nodes Wirin...

Page 42: ...inge application Hoppers deliver screws to Six Shooters by way of a air tube Six Shooters drop down and drill hinge into place on jamb and the door edge FIGURE 2 4 Front Section Carriage Head 1 Carriage Head 2 Carriage Head 3 Screws Transported Six Shooter 1 Carriage Head 4 Six Shooter 2 Six Shooter 3 Six Shooter 4 When processing 8 0 doors all Carriage Heads and Six Shooters are used to pro cess ...

Page 43: ...cket on the door and jamb A pre drill to drill pilot holes in the hinge pockets to ready the insertion of screws by the six shooter FIGURE 2 5 Hinge Carriage Screw Driver Bits Router Bit Router Motor Air Drive Pre Drill Drills pilot holes for insertion of screws on the jamb and the door Air Driven Router Routs the hinge pocket on the jamb and the door at the same time as the counter rotate router ...

Page 44: ...nge to the hinge pockets and then attaches them with six screws on the jamb and the door The Hopper Rotary Bank Option Hoppers deliver the screws to the six shooters indicated below About the Hopper Review to the figure below for identification of Hopper assemblies See Hopper Pro cess on page 2 15 for operation descriptions FIGURE 2 6 Hopper Part Call Outs Screw Track ing Plate Assembly Gate Assem...

Page 45: ...f screws delivered to the to the Screw Tracking Plate Assembly 6 Press Hinges Loaded on the Six Shooter Control panel to activate the Slide Assembly to drop the screws into the Screw Delivery Tubes 7 Each tube has air injectors to speed the delivery to the Screw Receiver Tubes Quick Change Process Some Six Shooter Systems have an a quick change option to quickly change to differ ent colored screws...

Page 46: ...on 12 Fill the Hopper with new screws About the Six Shooter Assembly Settings for the Six Shooter assemblies are entered in the User Interface Door is automatically positioned while the operator loads and clamps a hinge jamb Routing and boring occur while the operator places hinges into the nests of the hinge applicators The Figures in this section illustrate the Six Shooter Hoppers on Machine FIG...

Page 47: ...he move to the side for Maintenance and Manual application of Hinges Vertical Rails Tube Frame Delivers Screws to Hinge Applicator by way of plas tic tubes Driver Assembly Hinge Application Vertical Cylinder Drives Six Shooter Up and Down Spring Tension for vertical movement Note Air brakes are located on the vertical rails The brakes will operate when air pressure goes down a set reference level ...

Page 48: ...Index Spacers X2 Factory set to align hinge Screw Receiver Tubes These tubes receive the screws from the hopper by way of plastic tubes Latch Arm Latches to H Block to secure in place Latch Arm Cylinder Moves latch arm in and out of position Air Motor Gearbox Geared to drive 6 screws simultane ously Chucks X6 Holds 6 screws aligned to the Door and the Jamb Hinge Applicator Location to attach Hinge...

Page 49: ... Works in partnership with front section process Includes faceplate routing Includes boring for lock and bolt Front View of Rear Section FIGURE 2 10 Key Assemblies on the Back Section View from Front Section Back Section Valve Bank Lock Bore Motor and Drill Drills locks holes on the face of the door Chip Out Loca tion Lock Bore Bolt Drill Motor Machines Hole for Bolt Self Centering X axis Cen ters...

Page 50: ...11 Key Assemblies on the Back Section Back View Bolt Drill Extend and Retract Cylinder Oil Reservoir Lock Bore Extend and Retract Cylinder Lock Bore Limit Switches Face Plate Motor and Drill Routs face plate Edge Clamp Clamps edge of door Edge Clamp Clamps edge of door Deep Shallow Retracted ...

Page 51: ... to send out door FIGURE 2 12 Key Assemblies on the Out Feed Section Opt Dust Collection Blow Off Nozzles Valve Bank Back Section Air Input System Out Feed System The processed Door is fed to the next machine Sen sors detect position of door and when to send it out Hydraulic Tanks for Six Shooters Supplies hydraulic pressure to operate Six Shooter Front Section ...

Page 52: ...n Electrical Panel FIGURE 2 13 Main Electrical Box Overview The Main Electrical Panel Supplies voltages to the machine Contains the PLC Programma ble Logic Controller Contains servo drives to interact with the servo motors Axis and Lock Location in the front and back sections The High Frequency Panel Supplies voltages to the machine Contains the PLC interface VFDs Variable Frequency Drives to inte...

Page 53: ...sors width adjusts and tool interfaces FIGURE 2 15 Sample of a Frame Node VFD Section Hinge Routere 1 4 Face Plate Router Feed Motor Width Adjust PLC Interface 120Vac 24 VDC Terminals Input Output Terminals High Voltage Section Disconnect PDR Power Dist Connector Fuses Contactors and Thermal Over load Circuits Lock Bore Screw Drivers 1 4 Bolt Drill PLC Interface Top Ethernet cable is from PLC Bott...

Page 54: ...URE 2 16 Location of Nodes on Machine Main E Box Contains Servo Drives Network Connections power and Inputs Outputs originate from this box and are connected to Nodes Network Connections Power Distributed to Points in the machine High Freq Box Power Distributed to Points in the machine Frame Node Screw Driver 1 Screw Driver 2 Screw Driver 3 Screw Driver 4 Back Section Node ...

Page 55: ...and right hand doors for drive in ball catches When selected the proper drill automatically pivots in to drill into the top of the door minimum door width for drilling is 18 FIGURE 2 17 Location of Ball Catch Drills Option N Dust Blow off System Air blow off tube cleans dust and chips from the top of a door Located on the Outfeed of machine FIGURE 2 18 Air Blow off Front of Machine Ball Catch Left...

Page 56: ... Stop for 8 0 doors Air Cylinder for Hinge Router Shifts for 6 8 8 0 Retractable Six Shooter for loading in jambs servo motor driven About the Shift Function The Shift In Function moves Car riages 1 2 3 and 4 into working posi tion Shift In Shift Out The Shift Out Function moves Car riages 1 2 3 and 4 into a position to allow the operator into the machine processing area Allows the operator to ins...

Page 57: ...e valve that is interlocked with a safety switch to disable the staple guns unless there is a jamb clamped in the machine To Use this Function 1 Enable by selecting the Split Jamb Stapler button Green Located on the Main Screen 2 Load the male split jamb into the female slot of the jamb 3 Load jamb assembly into machine 4 During process The split jamb will auto trigger the fir ing mechanism of the...

Page 58: ...anging hoppers for changing screw colors Enables the operator to change or add screws at floor height Set up containers to catch the screws 1 Select the Manual Screen Tab 2 Press the Quick Dump Hopper Button 3 Pour new screw style into each hopper 4 Continue processing doors Dump Area ...

Page 59: ...ndary side of transformer 2 Overload Relay Checks the Overload Relay in the E Box In some cases this circuit is jumped In these cases it should always light when the Control Power turns on 3 E Stop All gates are closed and the E stops are not activated when this light is on 4 Stop This light will be on if Machine Stop button is deactivated 5 Start This light will be on once the Machine Start butto...

Page 60: ... 2 Turn on the Red Power Lever at each Electrical Panel 3 Turn on each Green Control Transformer Lever on the Operators Station After the computer is completed booting up the Interface will start automatically However for instruction purposes below are manual steps to start the programs DoubleClickthe desktop icon Press the Hinge Loaded button to start the pro cess Select the Home Machine Line But...

Page 61: ... Pusher is Enabled and Auto Door Width is Enabled If processing split jambs enable the Split Jamb function After the machines have the Home sequence and door is fed in and auto clamped perform these steps While loading the jamb it is important to be mindful of the placement of your hands If hands are in the wrong place when the jamb is being loaded the jamb clamp could crush hands 1 Load Jamb on t...

Page 62: ...ards the top of the door Each of the three Six Shooter heads has a hinge pocket in which to place one hinge The hinge pocket is magnetic and will hold the hinge in place 5 Move out of area beyond the Light Curtain 6 When outside of Light Curtain press the Hinge Loaded button to start the process 7 Repeat from Step Load Jamb until completed Take Note of the Status Blink codes ...

Page 63: ...Power Up the Line 1 Ensure factory air is applied to each machine and main air supply is turned on 2 Check that all E Stop buttons are out and safety gates are closed Note A pop up is displayed on the user screen if an E Stop is pressed The pop up will indicate which E Stop has been activated 3 Make sure the electrical disconnect each electrical cabinet is turned to the ON position 4 Switch the gr...

Page 64: ...the Home button on the Main Screen touch screen 6 Initiate the Hinge Loaded to act as a Reset Note This process is a safety precaution to ensure the no personnel is in the machine staging area Push the Hinge Loaded Button 7 All lights on the status light panels on the electrical box should be illuminated Note If a status light does not turn on during the power up process see the trouble shooting c...

Page 65: ...s to OFF this helps reduce possible damage resulting from power surges from electri cal storms Emergency Shutdown and Recovery There are emergency shutdown E Stop switch located at key points around the machine 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 The mach...

Page 66: ...eshoot the 990 FX Screen Selection Menu Map Below are the menu selections for the 990 FX FIGURE 2 19 Main Menu Opening Screen Set Presets to machine the doors See About the Main Screen on page 2 38 Manual Menu Control the machine manually through this screen See About Manual Operation on page 2 43 Setup Screen Calibrate the position of the lock location See About the Setup Screen on page 2 47 Diag...

Page 67: ...at the bottom right hand cor ner of all user screens is status feedback information The information generated is as follows 1 General Machine Status 2 Front Section Status 3 Back Section Status 4 Current Servo Positions Note Use this information to isolate issues if having problems with the machine 1 2 3 4 ...

Page 68: ...ut the Main Screen The Main Screen is also the startup screen for the 990 FX From this screen all the basic user interface controls are available to run a door FIGURE 2 20 Main Screen Note Call outs A and B are commonly used buttons and appear on all the screens ...

Page 69: ...time the machine is powered up or reset If a fault occurs that cannot be cleared press the Reset but ton This button will reset the machine to the start position before homing Note Press Home Machine after Reset Machine This button stops the door in the process This button shuts down the computer Use this button as part of the shutdown pro cess See Initial Powering Operations for the 990 FX Line o...

Page 70: ...door after machining is completed Auto Width Press Auto Width to toggle the auto width on or off In auto mode the sys tem will auto adjust to the width of the door that is being processed Jump Buttons These buttons allow movement to each screen Main This Section Manual See About Manual Operation on page 2 43 Setup See About the Setup Screen on page 2 47 Diagnostics See About the Setup Screen on pa...

Page 71: ... in which to save the parameters 2 Name it to an appropriate label 3 Select the save button to save to memory Head 2 Router Initiate for 3 Hinge doors Routers Press to Enable or Disable the Routers in Head 2 Hinges Group Set the parameters for the hinges in the Hinge Spec group Push desired buttons to select specification or toggle state Hinges Hinges Press to Enable or Disable all the Hinges Rout...

Page 72: ... Securing Split Jambs on page 2 27 Settings include Lock Press the Lock button to enable or disable the lock section machining process If disabled the back section will not machine the door Lock 1 3 Set the lock position Lock Bore Press the Lock Bore button to enable or disable the Lock Bore Bolt Drill Press the Bolt Drill button to enable or disable the Bolt Drill Face Plate Press the Face Plate ...

Page 73: ...Service Manual About Manual Operation From this screen you can control certain functions of the machine in manual mode This screen is mainly used in troubleshooting checking cut specifications and maintenance FIGURE 2 21 Manual Operation Screen ...

Page 74: ...arriage will also stop if the negative travel limit eye is acti vated Feed Manual Control Feed Reverse Press and hold the Reverse button reverse the feed of the door To stop the feed release the button Forward Press and hold the Forward button to move the door feed forward To stop the feed release the button Normal Speed Press and hold the Normal Speed button to slow speed To return to previ ous s...

Page 75: ...ished Burn Chipout Use this button if a new Chipout Block is installed on the lock section Press to start the burn sequence A new hole will be slowly drilled the process will automatically stop when finished Hinge Manual Control Hinge Carriage Location Up Press and hold the UP button move the Hinge Carriage up Release the button to Stop Jog Down Press and hold Down to move the Hinge Carriage down ...

Page 76: ...em Drive screws through tubes Shift Drivers In Out The In button shifts the six shooters over hinges The Out button shifts the six shooter out of position Test Mode and Hinge Burn Chipout Command Code Displays current command code Activate Command Press to actuate the command code in the box Test Mode Select to toggle the Test Mode on or off Test Mode runs the hinge cycle but does not extend the t...

Page 77: ...not in specification Enter a Positive or Negative Number Determine when to enter a positive of negative number by using your Left Hand Use the cut on the door as a reference Hold out the left hand with the first finger pointed at the cut on the door second finger and thumb at right angle to each other The first finger represents the positive direc tion of the Z axis the thumb represents the positi...

Page 78: ...ntact the KVAL Service Center KVAL Inc 1 800 553 5825 See Getting Help from KVAL on page 1 14 5 Run a test door again to verify the offset correction was successful 6 Keep running a test door and adjusting the offset until satisfied with the result 7 After satisfied click the Combine with Base button to store the calibration Y Y X Axis Positive movement Z Axis Positive movement Y Axis Posi tive mo...

Page 79: ...e dis tances of the LH and RH Stops from the Home Limit as a ref erence 6 8 and 8 0 Tunes the distance of the stops from the reference HOME for LH and RH doors of each door length Note 8 0 Door is an Option To start run a known good lock cut at a standard location on a Right Hand or Left Hand door Once the lock cut is completed check the distance from the top of the door to the center of the lock ...

Page 80: ...easure again and repeat steps 3 to 4 until the center of the lock is at the desired cut location 7 Once the completed with calibration select the Combine with Base button to store the data 8 Exit Main Calibration Screen Timing Front Section and Back Section Use the Timing Controls to tune the synchronization of the Carriage Head routine and the Face Plate routine If Either process is finishing too...

Page 81: ...cated after the Before Out feed eye Screw Shift Heads 1 and 2 Heads 3 and 4 Adjust the Screw Shift locations for Heads 1 2 and Heads 3 4 The Out Parameter corresponds to the position when the Heads are parked and out of the way The In parameters correspond when to Heads are located in the middle of the machine getting read to process the door The figure below is a view form the back of the machine...

Page 82: ...ine issue can not be resolved call KVAL Inc 1 800 553 5825 Have any error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten down time The Diagnostic screen keeps track of the all the doors processed on the machine The quantity is displayed in the Total Door Count box To keep track of daily production the quantity of doors produced in a day is...

Page 83: ...of doors pro cessed through out the day This is additive until reset Reset Count Push to reset the Daily count of doors The Door Count box keeps track of all doors processed on the machine and the daily count of doors processed The Total door count cannot be reset The Daily count can be reset Use the daily count to keep track of the throughput of daily manufacturing ...

Page 84: ...t when pressed activates the door clamp to either clamp or unclamp the door Jamb Clamp Pedal The jamb clamp pedal is a foot pedal that when pressed activates the jamb clamps to clamp the jamb in place Routers Routers are located in on the lower front section to rout for hinges as well as a router on the back section to rout for the faceplate Six Shooters The Six Shooters are housed in the four mov...

Page 85: ...Glossary of Common Terms 2 55 KVAL Operation Service Manual ...

Page 86: ...oller is an on board 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 Section Name Summary Page System IT Administration A brief overview of the PLC operations page 3 2 ...

Page 87: ...e also contains internal main memory The computer has a removable Compact Flash card from which it boots The controller uses a Windows 7 oper ating system with TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include A smart power supply to connect to EtherCat terminals This supply contains a LCD to display system and user messages A DVI USB module to con...

Page 88: ...ur data on a regular occur rence The KVAL service team would be happy to help If any questions occur contact our service team at 800 553 5825 or at www kvalinc com Procedure for Backing up Data 1 On desktop double click on the Beckhoff Backup bat icon Let it run its course and compress the files Once it is done Press any key to Continue Backup is com plete 2 Go to C 00 Backup Folder Look in the fo...

Page 89: ...powerful tool to help fix issues that occur with the Vision Line machine With the remote access our KVAL service technician is able to observe your user screen in real time read and adjust programming code For Vision Line access the Intranet connection on the machine controller must have outside access to the Internet ...

Page 90: ...System IT Administration 3 5 KVAL Operation Service Manual ...

Page 91: ...o machine cycle times and describes the suggested maintenance steps to perform 300 Cycles 600 Cycles 3 000 Cycles 12 000 Cycles 72 000 Cycles page 4 2 Tool Changing4040 Schedule Describes the suggested time frame to change the tools in the machine page 4 14 Lubrication Requirements This section describes the lubrication requirements for the machine including types of lube to use This section inclu...

Page 92: ...0 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 Tools Screw Driver Bits Lubricate Lu...

Page 93: ...bearings if applicable Clean Clean all bearing shafts with clean dry cloth 12 000 Cycles Inspect Inspect chains for proper tension or damage Inspect Inspect all air cylinders for air leaks Replace if seal is leaking Inspect Inspect hydraulic lines for loose fittings leaks and cracks Inspect Inspect ball rail shafts for pitting or abrasions Lubricate Clean and lubricate all slides and cylinder rods...

Page 94: ... 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 Front Section Underneath Car riage Heads Jamb Clamp area High Dust Accumulation Areas Lock Bore Area build up can occur and stop Bolt drill...

Page 95: ...ec 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 Screw Driver Bits See Replacing Bits in the Front Section on page 4 31 and see Replacing Tooling in the Back Se...

Page 96: ... dust filters Dust collection systems vary from machine to machine Follow manufacturers directions to empty dust collection units FIGURE 4 1 Typical Dust Collection Unit Lubricate the inside of the Hoppers with a light coat of dry silicone spray Lubricate the input to the screw drop hoses Provides an easier screw drop Do not over spray oil Filters Dust Collection Containers ...

Page 97: ...ge Check belts for cuts and nicks Belts can stretch over time Check for looseness A rule of thumb is to pull belt if belt moves too freely then replace belt Belts can become slick from use lesson ing traction on door Check belts for slickness or door slippage Inspect screw drop tubes for kinks cracks wear from rubbing Ensure tube clamps are tight Inspect all photo eyes secure and tight Check Conne...

Page 98: ...at 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 screw receiver parts on six shooters for cracks or breaks Inspect 1 Screw Receiver 2 Spring 3 Split Shell 4 Steel Ring 5 Rubber Ring 6 Steel Ring ...

Page 99: ...ll airline connections assem blies air valves and hoses Check from source to end assembly Check Hoses for kinks and rubbing manifold connections and Air Cylinder connections Ensure Air is turned off Refill all lubricators Replace fluid if milky or discolored Use ab ISO 32 stan dard hydraulic oil KVAL PN SYS LUBEG Slide locking switch down twist bowl and remove Refill bowl Reverse action when insta...

Page 100: ...l 4 10 Grease Ball Screw Bearings Grease ball screw bearings if applicable For a table of lubrication types to use Lubrication Schedule Clean Bearing Shafts Clean all bearing shafts with clean dry cloth Spray shaft with silicone oil and clean build up grime and dirt ...

Page 101: ...if seal is leaking Symptoms include a cylinder not extracting or retracting to the limits Cylinders not holding their position Inspect Hydraulic Lines Inspect chains for proper tension or damage Check for sagging chains Chains can stretch over time of use Check for chain stiffness Stiff chains do not provide a tight fit over the gears Inspect hydraulic lines for loose fittings leaks and cracks Ins...

Page 102: ...ides Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray Clean inside Hopper Inspect ball rail shafts for pitting or abrasions Example of a Pitted Ball Rail Clean inside hopper with dry sili cone oil and a 3M ScotchBrite pad or equivalent Wipe dry with a clean dry rag ...

Page 103: ...tions 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 Check that there is a smooth transition with a door feeding into and out of machine Feed door in and out to verify smooth tran sition is repeatable Wash filter and lubricator bowls with soapy water Slide lock down to...

Page 104: ...isels Inserts 1500 cycles Chip Out Block 10 000 20 000 cycles 9 64 Pre Drill Bit 10 000 20 000 cycles 1 8 Pre Drill Bit 10 000 20 000 cycles Lock Section Tooling Face Plate Router Bit 2 500 cycles 2 1 8 Face Bore Bit 2 500 cycles 2 1 8 Face Bore Bit Inserts 2 500 cycles Insert Scoring Spur for 2 1 8 Bit 2 500 cycles Face Bore Chip Out Block 2 500 cycles 1 Bolt Drill Bit 2 500 cycles Prior to perfo...

Page 105: ...AL 990 FX Operation Service Manual Screw Receiver and 6 Shooter Tooling Screwdriver Bits 1 500 cycles Steel Rings 7 500 cycles Rubber Rings 7 500 cycles Screw Receivers 30 000 cycles Split Shells 30 000 cycles Springs 30 000 cycles ...

Page 106: ...hese conditions are changed timing accuracy or damage may occur during the machine process Do not adjust air PSI above or below factory settings Do not adjust any and all flow controls from factory settings Do not remove shim stock Do not Change or Alter any safety assemblies E Stops Gate Locks etc Do not Change programs in PLC s or PC s Do not Alter Electrical Components ...

Page 107: ...llow Block Bearing Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Note Some CNC Machines drop every 5 10 cycles Either lubricant listed below is approved to use KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32 Gulf Harmony 32 Gear...

Page 108: ... Block Bearing Idler Shaft Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Tapered Bearing Once 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...

Page 109: ...rk fitting 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 cle...

Page 110: ...for reliable operation FIGURE 4 3 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 4 4 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 Ev...

Page 111: ... is such an asset that the bearing blocks often require little maintenance for the life of the machine FIGURE 4 5 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 4...

Page 112: ...a Typical Ball Nut Ball Screw Drive Assembly Including the Ball Screw Nut other types of bearings may be included on the assembly The figure below shows a typical Ball Screw Drive Assembly FIGURE 4 8 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...

Page 113: ...the door in and out of the machine Each pulley contains an idler shaft that has a zerk fitting to apply grease An opening in the idler shaft dispenses grease to the inner diameter of the pulley Pulley in Action Breakout of Pulley Assembly Grease IN Grease Out Note It is important not to overfill the Idler Shaft Avoid get ting excess grease on the belts Idler Shaft ...

Page 114: ...gure below shows location of the servo motor assemblies Grease according to intervals described in See Grease Ball Screw Bearings on page 4 10 FIGURE4 9 Feed System Lubrication Points Use Lube EP2 or similar to Lubricate Chains Lubricate feed sys tem hex shaft with Silicon Spray Idler Shafts on the Pulleys in the Feed sys tem ...

Page 115: ...figure below shows location of the servo motor assemblies Grease according to intervals described in See Grease Ball Screw Bearings on page 4 10 FIGURE4 10 Screw Drive Lubrication Points Some Bearings are layered under plates Use a Needle adapter to get to hard accesses bearings X4 X4 X3 X1 X1 ...

Page 116: ...ows location of the servo motor assemblies Grease according to intervals described in See Grease Ball Screw Bearings on page 4 10 FIGURE4 11 Back Section Grease Points Back View Front View Back View 2 Bottom View Some Bear ings are lay ered under plates Use a Needle adapter to get to hard accesses bear ings ...

Page 117: ... of the servo motor assemblies Grease according to intervals described in See Grease Ball Screw Bearings on page 4 10 FIGURE4 12 Carriage Head Grease Points Assemblies shown transparent X4 X4 X2 X4 X4 Top X4 Back Bottom Some Bearings are lay ered under plates Use a Needle adapter to get to hard accesses bearings ...

Page 118: ...Assembly The figure below shows location of the servo motor assemblies Grease according to intervals described in See Grease Ball Screw Bearings on page 4 10 FIGURE4 13 Servo Motor Assembly Locations Heads 1 and 2 Shift Heads 3 and 4 Shift Lock Sample Servo Motor Assembly Back of Machine ...

Page 119: ...ers delivers the lubricated air to valve banks and air cylinders FIGURE 4 14 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 Clean Dry Air CDA to Air Blow Off Lubric...

Page 120: ...f Harmony 32 To prime the lubricator find an air line on the carriage section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose Repeat this same procedure for the back section and other trouble areas It is recommended to che...

Page 121: ...he locations of the replaceable parts inside the heads FIGURE4 16 Location of Bits in the 990 FX Heads 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 Screw Driver B...

Page 122: ...ver to access the bit assemblies Remove and Replace the Router or Pre Drill Bits After lockout tagout and access has been obtained to the assemblies follow these instructions to remove and replace the router bit or the pre drill bit 1 Use a 17 mm shaft wrench and a 3 8 collet wrench to remove the bit on the pre drill or router assemblies See FIGURE4 17 Removing Pre Drill or Router Bit 2 Inspect an...

Page 123: ...ase of the collet nut to the tip of the bit If available use the Router Bit Depth Gauge PN 432 C to set the depth of the drill Note Make sure the arbor is not bottomed out in the back of the motor If it is the arbor will not tighten and will damage the collet or other machine parts FIGURE4 19 Setting the Bit Depths Collet Spindle Collet Nut Verify that there is no damage or bluing on the side of t...

Page 124: ...oter heads follow the instructions below 1 Turn off all power to the machine Follow proper lockout tagout procedures as detailed in the safety section of Chapter 1 of this manual 2 Disconnect air from Six Shooter using the air connect slide valves Slowly slide the valves back toward you listen for air to be released 3 Pull the Six Shooter assembly toward the machine it will move slightly 4 Locate ...

Page 125: ...the machine Follow proper lockout tagout procedures as detailed in the safety section of Chapter 1 of this manual Follow the instructions in this section to change the bits on the Bore Drill Bolt Drill and the Face Plate Router Lock Bore Motor and Drill Drills locks holes on the face of the door Bolt Drill Motor Machines Hole for Bolt Face Plate Motor and Drill Routs face plate ...

Page 126: ...ith Access Tools OFF The Lock Plate will move to a position for easy access Lock Access Button with Access Tools ON Moves the Lock Plate out further if more room is needed to access tooling Changing the Bore Drill Ball Catch Drills 1 Remove Dust Collection Guard 2 Use the shaft wrench and collet wrench to remove the bit on the pre drill or router assemblies See photo When loosening the collet it m...

Page 127: ...amage the collet or other machine parts Note The figure shows the cover off for training purposes 1 Use the shaft wrench and collet wrench to remove the bit on the pre drill or router assemblies See photo When loosening the collet it may tighten up crack again and continue 2 Inspect and clean collet assembly 3 Insert the new bit into the assembly 4 Before tightening the collet assembly adjust the ...

Page 128: ...s KVAL 990 FX Operation Service Manual 4 38 Collet Torque Values KVAL recommends torquing the collets Torquing adds consistency is important for repeatable machining Follow the torque tool manufacturers method of torquing ...

Page 129: ...Collet Torque Values 4 39 KVAL 990 FX Operation Service Manual ...

Page 130: ...Collet Torque Values KVAL 990 FX Operation Service Manual 4 40 ...

Page 131: ...riptions of the basic operation of contactors VFD s and pneumatic controls page 5 7 Trouble Shooting Electrical A summary of electrical trouble shooting tips Includes descriptions of using the 6 lights to solve issues page 5 20 Using Sensors to Trouble shoot Information about the sensors page 5 26 Network System Overview Locations of network connections on the 990 FX page 5 30 Note Refer to the Ai...

Page 132: ... 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 drill s travel is limited by physical stops Incremental Incremental motion control is used when the load is required to be moved with high accuracy...

Page 133: ...ler 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 machine s other subsystems when the move process is completed Examples A PLC or a ded...

Page 134: ...t of specification Note See Table 5 1 on page 5 for sequence and subsystem information 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 Note See Analyze the Sub Systems on page 5 5 for information on verifying and analyzing subsystems Before you Adjust Sometimes simple prob...

Page 135: ...TABLE 5 1 Typical KVAL Machine Sequence Typical Machine Sequence Responsible Subsystem 1 Move Door into Position Feed System 2 Clamp the Door Door Clamp 3 Make the Cuts Cutter Positioning Cutter Power 4 Unclamp the Door Door Clamp 5 Move Door Out Feed System 6 Wait for Next Door Feed System Basic Troubleshooting Steps Determine Where The Sequence Step Where the Failure Occurs What was the Machine ...

Page 136: ...activated input is lit Some touch screens have inputs status also 3 Common Position Feedback failures Photo Eye a Bad element or bad cable b Eyes not set to correct height c Lighting from ceiling may be interfering with sensor Limit Switch Stuck or failure Wiring Broken worn insulation PLC Bad input port Bad Output Relay may be stuck Air Solenoid Valve May be stuck or not working 4 Check the Posit...

Page 137: ... Block 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 L...

Page 138: ...he circuit See Troubleshooting Electrical Prob lems on page 5 20 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 trippi...

Page 139: ...oltage may cause personnel injury or death Troubleshooting checks must be performed by a Qualified Electrical Technician Common Motor Drive Control PLC Output Fuse s Line Voltage Motor Power Motor Power Input Output Power Control Circuit Common ON Measure Control Voltage 24 VDC here Measure Line Voltage here Measure Line Voltage here ON Drive STF Forward RL STR Revers 2 SD COMMON OFF OFF OFF Run 3...

Page 140: ...diagram see Figure 5 18 on page 5 9 FIGURE 5 19 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 pu...

Page 141: ... printed on the button If a VFD is tripped to OFF the button will be lit To reset a VFD 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 motor circuit is not causing the issue b If issue continues read er...

Page 142: ...ram of a Pneumatic Circuit PLC Output High Pressure Air Cylinder Common Control Circuit ON Measure 24 VDC here Control Voltage Should have High Pressure air here Cylinder Control Control Coil Input Air Input Air Output Valve Should have High Pressure air on Activated Output Schematic Drawing of Pneumatic Circuit Note Pre 2006 machines may not contain the 24 Volt relay 120 Vac is directly fed into ...

Page 143: ...o the solenoid body Use this information to troubleshoot system if nec essary FIGURE 5 23 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 ...

Page 144: ...escribes 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 activa...

Page 145: ...e Cylinder and Router retract deactivating the Extend Sensor 3 When the Cylinder and Router are fully retracted the Retract Sensor is activated 4 The PLC senses the voltage from the Retract Sensor completing the process Positioning System Load Force Translated Positioning PLC Instructions Position Feedback Extend Sensor Retracted Sensor Deactivated Activated 24 Volts Extended Cylinder 24 V Applied...

Page 146: ...ckets and flipping screws in Hoppers However sometimes machine settling mechanics be broken in may be cause to slightly adjust extend and retraction speed If more than 1 2 turn on adjustment knobs are needed call in a specialist or check with KVAL customer service at 1 800 553 5825 Cylinder 0 V Router Assembly Load Position Feed Back Air In Control Valve Retract Sensor Activated Air Pressure Retra...

Page 147: ...Operation 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 148: ...voltage 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 Note Labels on the solenoids identify loads they control Location of Valve Banks on the Edge SS FIGURE 5 25 Location of Valve Banks Back Section Screw Driver 4 Screw Driver 3 Screw Driver 2 Screw Driver 1 In Feed O...

Page 149: ...ll Plunge 1 4 3 Router Plunge Horizontal 1 1 4 Vertical 1 7 8 Vertical 8 Vertical Out Feed Extend and Retract 2 Router Plunge 2 Pre Drill Plunge 4 Router Plunge 4 Pre Drill Plunge Air to Pre Drill 4 Pre Drill Blow Off 4 Swing Clamp 6 8 Out Feed Door Stops Out Feed Door Jamb OPT Split Jamb Stapler Screw Driver 1 4 3 Extend and Retract Head A Up B Down Head in Position Head In and Locked Door Clamp ...

Page 150: ...ch circuits are failing by watching the lights turn on or off Compare the lights on the IDEC or Beckhoff controllers to the electrical print to determine what systems are being affected If the Power Stops During Normal Operation 1 Check that the input power disconnect switch is not turned off 2 Check that all of the emergency stop buttons are in the normal position 3 Check the Six Lights on the El...

Page 151: ... Variable Frequency Drives interact with hinge and faceplate routers width adjust motors and feed motors If issues occur error codes are displayed on the VFDs To help troubleshoot refer to the VFD manuals located in the High Frequency Panel for lists of the error codes See About the Electrical Panels on page 2 62 for locations of VFDs Troubleshooting with the Status Light Panel The Status Light Pa...

Page 152: ... A on page 5 23 STEP 2 Overload Relay Amber If light is OFF go to item B on page 5 24 STEP 3 E Stop Amber If light is OFF go to item C on page 5 24 STEP 4 Stop Amber If light is OFF go to item D on page 5 24 STEP 5 Start Amber If light is OFF go to item E on page 5 25 STEP 6 24VDC Green light is OFF go to item F on page 5 25 The sequence that the lights turn on are as follows 1 Control Power Amber...

Page 153: ...to the top of the Control Transformer replace the Control Transformer 6 If there is power at the Control Transformer check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip 2 Is the Disconnect Switch on the main electrical cabinet set to ON Switch 3 Is there 208 220 440 or 575 VAC to the top side input of the Control Trans former If not check t...

Page 154: ...Trip Indicator Factory Set Current Rating Adjust E Stop Light OFF Check to see the if any E Stop buttons are pulled out NOTE Location and quantity of E Stop buttons varies depending on customer need Typical locations for E Stop buttons are near the Rear Access Gate and near the Tool Changer Access Gate Stop Light OFF Check for 110 VAC between 2 and 4 If there is voltage press the Start button If n...

Page 155: ... 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 output wires to the 24VDC power supply Trace the output wire to the DC terminal block Disconnect all 24V positive wires from the DC from the DC terminal block except the output wire from the 24VDC ...

Page 156: ...sors often get dirty Make sure they are clean If they are not clean debris blocks the signal Check output voltages of the sensors in the active mode The voltage should effec tively equal 0 VDC Check the output voltages of the sensors in inactive mode The voltage should effec tively equal 24 VDC Location of Sensors on 990 FX Figure 5 27 below shows the typical sensor locations on the 990 FX The I d...

Page 157: ... Inside Door Sense Eye Before In Feed Stop Screw Drive Head Out 1 Door In Machine After Out Feed Stop Eye After In Feed Stop Screw Drive Head Out 2 Screw Drive Head In 2 Screw Drive Head In 3 Screw Drive Head In 1 Screw Drive Head Out 3 Width Adjust ment Sensors Valve Bank 1 Width Adjust ment Sensors Valve Bank 2 Q Des Valve Bank 3 Q Designators Out Feed Stop Eye Valve Bank 4 5 ...

Page 158: ...ts in positive and negative depth move ment and also sets the home position Note Below is an example of a Standard 990 FX with 3 Carriage Heads Other Options may include a 4 Carriage Head version or Hoppers that are a separate array to the side The 4th Carriage option follows the same sensor placements as Carriages 1 3 FIGURE 5 28 Figure 5 28 Section View of 990 FX Y Axis and Z Axis Sensors Hinge ...

Page 159: ...e home position The sensors are located underneath the Heads Below is an example of a Standard 990 FX with 3 Carriage Heads Other Options may include a 4 Carriage Head version or Hoppers that are a separate array to the side The 4th Carriage option follows the same sensor placements as Carriages 1 3 FIGURE 5 29 Bottom View of 990 FX location of X Axis Sensors Hinge 1 Hinge 2 Hinge 3 X Axis Home Ey...

Page 160: ...r machine s schematic package for detailed wiring information To aid in troubleshooting the next section shows the locations of the assemblies in the block digram below Connections to Servo Drives The Servo Drives are located in the Main Electrical Panel The outputs connect to the following For detailed wiring information see your machine s electrical drawings FIGURE 5 30 Servo Drives 24 VDC Input...

Page 161: ...nd outputs for the following VFD s The front section routers counter rotate routers and pre drills The back section lock bore and bolt drill Hinge P2P Door width outputs to the stacker For detailed wiring information see your machine s electrical drawings FIGURE 5 31 High Frequency Node Sample Coupler PLC Interface 4 7 2 1 6 5 8 3 Inputs Outputs Ether CAT Output To E Stop Circuitry Ether CAT Input...

Page 162: ...y to the side FIGURE 5 32 Node Locations of a 3 Head and 4 Head Machine Screw Driver Node 1 3 Back Section Node F N d Frame Node Main E Box Contains Servo Drives Network Connections power and Inputs Outputs originate from this box and are connected to Nodes Network Connections Power Distributed to Points in the machine High Freq Box Power Distributed to Points in the machine Frame Node Back Sectio...

Page 163: ...pt 4 The Screw Driver Nodes are located on the back of each of the three Six Shooter assembies In summary these nodes include the following Six shooter inputs and outputs Hopper inputs and outputs Screw driver related inputs and outputs For detailed wiring information see your machine s electrical drawings Back Section Node The Back Section Node is located on the back section of the machine In sum...

Page 164: ...Network System Overview KVAL Operation Service Manual 5 34 ...

Page 165: ...ation2 47 chisels replacing4 27 collet assembly inspection4 28 4 32 4 33 computer as a PLC3 2 backing up3 2 3 3 control panel light not on troubleshoot5 23 control power indicator light description2 27 2 31 control transformer switch power up2 31 2 33 D diagnostic screen description2 50 door spec group description2 38 drill bit replacing4 27 dura lith grease bearing lube4 17 DVI USB module locatio...

Page 166: ...in screen interface2 36 manual operation interface2 41 menu map2 34 N network system overview5 30 nodes back section5 33 frame connections5 33 high frequency inputs outputs5 31 high frequency locations5 31 screw drivers 1 35 33 O out feed key assemblies2 21 overload relay light description2 27 P pillow block bearing maintenance schedule4 17 PLC battery location3 2 connections3 2 location3 2 locati...

Page 167: ...up screens2 45 shut down system description user interface2 37 six light panel description2 27 sequence list2 27 start light description5 25 start light description2 27 start machine button power up2 31 status light panel description5 21 use as troubleshooting key5 21 stop light description2 27 stop sequence button description user interface2 37 T tagout procedure1 10 troubleshooting using status ...

Page 168: ...KVAL 990 FX Operation Service Manual ...

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Page 172: ...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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