Kval Edge-SS Operation & Service Manual Download Page 13

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KVAL Operation/Service Manual

CHAPTER 1

Introduction to the Edge-SS System

Chapter 1 at a Glance

The following information is available in this chapter:

TABLE 1- 1.

Summary of Chapter

Section Name

Summary

Page

page 1-2

Safety First!

IMPORTANT safety information is
described in this section

page 1-5

Lockout-Tagout Guidelines

Procedures describing Lockout Tagout.

page 1-9

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 con-
tact the KVAL service center for help. The
section includes how to get information from
the specification plate tor provide to KVAL,
service center hours, and return procedures

page 1-14

Safety Sign-Off Sheet

A record to track operators that are trained
on the machine.

page 1-19

Overview of the Edge-SS Door

System

This section provides an overview of the
machine. It includes a general description and a
table of available options

Summary of Contents for Edge-SS

Page 1: ...Innovation Quality Honesty Operation Service Manual Published July 17 2018 Edge SS System Operation Service Manual Edge SS System ...

Page 2: ...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 Suppor...

Page 3: ...r 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 ab...

Page 4: ...hts in the content generated through the KVALCAM Software are also the property of the Licensor and are protected by applicable law 1 Definitions a KVALCAM Software means the KVALCAM computer application installed in the KVAL Machinery and written documentation and materials provided to you as well as any revisions or updates of such computer application and documentation b Install means storing o...

Page 5: ...KVAL Edge SS Operation Service Manual ...

Page 6: ... 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 Chapter 2 Operation of the Edge SS Line About the Edge SS Pr...

Page 7: ...Light Panel 2 17 Home the Machine Line 2 18 How to Power Down the Machine 2 18 Machine Start Summary 2 19 Summary of the KvalCAM Interface 2 22 Libraries and Machine Line Screens 2 22 Machine Control and Calibration Screens 2 22 Summary of the KvalCAM Interface 2 24 Libraries and Machine Line Screens 2 24 Machine Control and Calibration Screens 2 24 Status and Log Screens 2 25 About Machine Status...

Page 8: ...2 54 Chapter 3 Calibration of the Edge SS Line About Calibration 3 2 About the Calibration Menus and the Calibration Reference Cut 3 2 Before you Calibrate 3 2 About the Calibration Tabs 3 3 Access to the Calibration Adjustments 3 3 Unlock the Calibration Option 3 4 Enter a Positive or Negative Number 3 4 Axis Direction for the Edge SS Front Section 3 5 How to Enter Calibration Data 3 6 About Rest...

Page 9: ...ters 5 6 Empty Dust Collection Units 5 6 3 000 Cycle Maintenance Steps 5 7 Inspect Feed Belts 5 7 Inspect all Photo Eyes 5 7 Inspect Limit Switches 5 7 Inspect Airlines 5 8 Refill Lubricators 5 8 Grease Ball Screw Bearings 5 9 Clean Bearing Shafts 5 9 12 000 Cycle Maintenance Steps 5 10 Inspect Chains for Proper Tension 5 10 Inspect Air Cylinders 5 10 Inspect Hydraulic Lines 5 10 Inspect Ball Rail...

Page 10: ...5 22 Air Line Without Lubricator 5 23 How to Access to Bit Assemblies 5 24 Changing a Tool Bit and Using Tool Change Tightening Fixture 5 24 Remove and Replace the Router or Pre Drill Bits 5 24 About Chisels Option 5 27 Chisel Orientation on Machine 5 27 Changing Chisels on a Machine Option 5 28 Replacing the X Axis Self Lubricator 5 29 About the Automatic Lubricator 5 29 Collet Torque Values 5 32...

Page 11: ... Cylinder Speed 6 16 Adjusting Cylinder Extend Speed 6 17 Adjusting Cylinder Retraction Speed 6 17 Valve Bank Locations 6 18 Location of Valve Banks on the Edge SS 6 18 Network System Overview 6 19 Connections to Servo Drives 6 19 Edge SS Servo Motor Locations 6 20 About Switches and Sensors 6 21 Using Sensors to Trouble Shoot 6 22 About Checking the Revision Status 6 23 Troubleshooting Electrical...

Page 12: ...KVAL Edge SS Line Operation Service Manual ...

Page 13: ...o 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 con tact the KVAL service center for help The section includes how to get information from the specification plate tor provide to KVAL service center hours and return procedures page 1 14 Safety Sign Off Sheet A record to track operators that are trained ...

Page 14: ... increases pro ductivity by eliminating extra door clamping steps and reduces the chance of positioning errors Note Minimum sensing range for door touch off is 14 For doors less than 14 wide the exact width will need to be manually measured and entered into the Edge SS AC servomotors precision rack and pinion and ball screw drives are used for X Y and Z travel The X axis travel is 130 the Y axis t...

Page 15: ... flush bolt then move down to machine a dead bolt plate a T strike then and the bottom manual flush bolt The machine tabletop is L shaped and consists of inverted caster wheels so doors are easy to position The L shape allows routing of either rails or stiles by rotating the door Three door stops are provided at 4 intervals The first stop at the corner of the L table is used for both stile and rai...

Page 16: ...e Line and Safety Information Chapter 2 Operation Interface Descriptions of how to power machine line and operator inter face user screens Chapter 3 Calibration Descriptions of Calibration Rou tines and how to use the interfaces Chapter 4 System IT Administration Descriptions of the PLC system and computer system Chapter 5 Maintenance Maintenance steps for the machine line Chapter 6 Trouble Shoot ...

Page 17: ... of Labels In addition to the nameplate KVAL machines may have other warning labels or decals that pro vide safety information to operators Safety labels should be clearly visible to the operator and must be replaced if missing damaged or illegible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if the ...

Page 18: ... is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before performing any mainte nance or repairs on this...

Page 19: ...y repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out the electrical and air pressure systems This sho...

Page 20: ...machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed safety guidelines are included in the operating instructions of this manual KVAL will be pleased to review with you any questions you may have regarding the safe operation of this machine Follow Your Company s Safety...

Page 21: ...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 loc...

Page 22: ...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 Lockout Tagout Power 4 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to pop i...

Page 23: ...nce or repairs may started Post Maintenance Steps 9 After maintenance is completed the person performing the work must ensure all tools spare parts test equipment 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 condit...

Page 24: ...y 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 comp...

Page 25: ... 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 26: ...AM to 1 30 PM Pacific Standard Time Friday On Line Help On machines with a Beckhoff PLC and an internet connection our service team are able to con nect run and troubleshoot your machine Ask about this procedure when calling are service team 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 p...

Page 27: ...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 are...

Page 28: ...m 2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Google w...

Page 29: ...ield Enter your name The KVAL tech nician will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connec tion to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support App is loaded and completed call the KVAL service center 1 800 553 5825 an...

Page 30: ...How to Download the Service Application 1 18 KVAL Operation Service Manual Page Intentionally Left Blank ...

Page 31: ...low 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 electric...

Page 32: ...Safety Sign Off Sheet 1 20 KVAL Operation Service Manual ...

Page 33: ...nch out All Feature Groups have their own L T and W location that is separate from the features contained inside This allows the user to quickly move templates to new locations or to duplicate templates in multiple locations by adding new locations to the group Feature Group Name This field is required when saving a new template Feature Features are created by adding children to a feature group Al...

Page 34: ...Red only appears if the expression cannot be interpreted to a real number for validation while orange appears if the line cannot perform the cut Validation Report Validation will only work if the information that is fed to the machine line is accu rate Inaccurate information that is downloaded from Tool Configurations Calibra tions or Libraries e g material types will produce unexpected or potenti...

Page 35: ...Definitions 2 45 KVAL Operation Service Manual ...

Page 36: ...page 2 13 Initial Power Operations Description of powering up the line from the off state Includes Power down description Six Light Panel and homing the machine line page 2 16 Machine Start Summary A quick summary of running a door through the machine page 2 19 Summary of the KvalCam Interface A one page description of the KvalCam interface page 2 24 About the Libraries Screen Description of Libra...

Page 37: ...en and position door accordingly 9 After all cuts are completed press the Blue Door Finished Button to Feed the completed door into the next stage 3 Push the Door Stop Foot Pedal to pop up the stops 4 Position the door against the stop and fence according to the Operator s Screen 5 After the door is set press the Door Clamp Foot Pedal to secure the door Note If not clamped correctly press the clam...

Page 38: ...or hinge pockets T strikes concealed closures flush bolts leaf and European hinges end pivots as well as edge work for either cylindrical or deep pocket locks Many customers also use the Edge for re railing re stiling operations Control Roll Table Operators Station Electrical Panel 2 Electrical Panel 1 Rails Door Clamps Main Cutter Head Door Path Clamps Door Feeler ...

Page 39: ...l the edge of a door Operator Station The Operator s Station includes a touch screen and keyboard to run the program that operates the machine Note Multiple machine controls may combined in one station Machine Combinations are Cus tomer Definable Foot Pedal Controls Door Stops Door Clamps Emergency Stop Fence Clamps The Fence acts like a reference to align the door The clamps hold the door in plac...

Page 40: ...Stops Indicator Light The indicator light monitors the process of the cutting routine The visibility of the light allows observation of the progress of the machining in a factory environment TABLE 2 1 Indicator Light Descriptions Color Description of Process Red Machine in Error State Yellow Low Air Pressure X Axis Auto Greaser Empty Green Solid un Cutting Routine Blinking Ready to Start Blue No R...

Page 41: ...d through door clamping and door location It is important to keep the sen sors cleaned and aligned to keep the door process running smoothly There are two classifications of sensors on the Face SS Photo Electronic and Inductive Proximity Sensor Photo Eye Detector Emitter and Receiver in one package Proximity Detector Senses metallic objects Proximity Sensors Used on Cylinders ...

Page 42: ...er Rotate Hinge Router Routs the hinge pocket providing a clean cut Cylinders drives tools In and Out the door Deep Drill Z Axis Servo Motor Plunge Router Routs the lock hole in the door Main Plate Router Routs the Face plate pocket Deep Mortise Router Routs a deep pocket Zero Three Degree Cylinder Toggles the Head for 3 and 0 degree cuts X Axis Servo Motor Y Axis Servo Motor Electronic Node Conne...

Page 43: ...ders drives tools In and Out the door Counter Rotate Hinge Router Routs the hinge pocket providing a clean cut Main Plate Router Routs the Face plate pocket Deep Mortise Router Routs a deep pocket Y Axis Servo Motor Point to Point Drills pilot holes for insertion of screws on the door Assemblies on the Main Cutter Head KVAL Operation Service Manual 2 8 ...

Page 44: ...dex marker or reference that occurs at the same mechanical point of encoder shaft revolution This refer ence is used as a comparative point resulting in a highly accurate measurement The encoder assembly is identified as a Feeler Important If calibrating calibrate the Feelers first See Chapter 3 in this manual Typical Encoder About Door Length Feeler The Door Length Feeler accurately senses the le...

Page 45: ...of the door Then the accurate width is calculated The feeler and encoder is located at the in feed of the machine About Door Depth Feeler The Door Depth Feeler accurately senses the actual depth to drill This feeler and encoder are located on the Cutter Head After the door has been fed in to the door stop and clamped the feelers lightly tap the face of the door The feeler and encoder work with the...

Page 46: ...ts the hazard ous area and enables hazardous point protection access protection or hazardous area protection As soon as an person enters the protective field the safety laser scanner signals the detection The machine safely analyze the signals If the field is broken during cutting the machine will stop To recover if the field is broken 1 Push the START MACHINE button on the operator s station 2 Ho...

Page 47: ...factories pro cess the door with the narrow side up Verify the practice your company uses 3º 3º Up Door 1 Push Door against the back stop 2 Keeping Pressure against the back fence push the door against the appropriate stop Top and Bottom Cuts Hinge Side Use this position for Left Hand Top and Right Hand Bottom Edge Cuts Use this position for Left Hand Hinge and Right Hand Lock ...

Page 48: ...l of Entire Machine Line Download G code and Templates to set the specifications of door machining Manually control the door path and process through the line Machine diag nostics are included as well as internet sup port and connectivity for remote support via our Service Support Keyboard Enter data and interact with Touch Screen FIGURE 2 2 Operator s Station Operator s Screen Layout The Operator...

Page 49: ...he Edge SS Line on page 2 16 Edge SS Controls Start Sequence After templates and programs are loaded the doors are in place to process the machines is homed Press the Start Sequence but ton to run the machine line Door Finished Press if completed with job This clears the job Reload template after this button is pushed Edge Toggle Door edge selection This button adds the flexibility to over ride th...

Page 50: ... E Stop switches 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 high voltage power is cut to the machine The motors will stop however power to the PLC and the Operator Station Screen will remain on Note The machine responds in the same way if you press the...

Page 51: ...ck 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 green CONTROL TRANSFORMER switches to the ON positions They should light up 5 Push the green START MACHINE...

Page 52: ... secondary 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 ...

Page 53: ...line can be Homed using the Home Machine Line button located on the Machine Line Screen How to Power Down the Machine 1 1 2 3 Push the Stop button for each machine located on the Operator s Station 2 Shut down the operating system by selecting Shutdown from the Desktop Note Make sure Windows is shutdown completely before turning off the machine Hard drive or data may be dam aged if not turned off ...

Page 54: ...e is on 2 Turn on the Red Power Lever at each Electrical Panel 3 Turn on each Green Control Transformer Lever on the Operators Station Press each Green Start Button on the Operators Station to boot up into Desktop environment After the computer is completed booting up the KvalCAM User Interface will start automatically However for instruction purposes below are manual steps to start the programs D...

Page 55: ...ct the Add to Queue button Select a Door Job Select Libraries Tab Select Edit Verify or Modify Job Enter Qty Select Add to Queue Choose which door edge to pro cess first Check the Edge posi tion lights and use the Edge toggle button to select the desired edge Note Edge cut sequence defaults to optimal usage and favors hinge cuts last Press the 1 DOOR STOP pedal accord ing to set up 2 Position the ...

Page 56: ...d Stop button located on the Operators Station 2 Shut down the operating system by selecting Shutdown from the Desktop 3 After computer has fully shutdown turn off the Green Control Transformer lever on the Operators Station 4 Turn OFF the Red Power lever the Electrical Panels Machine Start Summary 2 21 KVAL Operation Service Manual ...

Page 57: ...t clone delete and download door jobs and door templates Power ful and flexible database of door cuts See About the Libraries Screen on page 2 27 Libraries Create edit clone delete View the entire process of the machine line queued jobs quantity and remaining doors and status of each machine Some line con trol is available See About the Machine Line Screen on page 2 35 Machine Line Machine Control...

Page 58: ...Tool Config From this screen set parameters for each tool in the Cutting Head See About the Tool Config Tabs on page 2 46 Summary of the KvalCAM Interface 2 23 KVAL Operation Service Manual ...

Page 59: ...ram operations Create edit clone delete and download door jobs and door templates Power ful and flexible database of door cuts See About the Libraries Screen on page 2 27 Libraries Create edit clone delete View the entire process of the machine line queued jobs quantity and remaining doors and status of each machine Some line con trol is available See About the Machine Line Screen on page 2 35 Mac...

Page 60: ...mmary of the KvalCAM Interface 2 25 KVAL Operation Service Manual Status and Log Screens Status From this screen check the status of the assemblies on the machine See what state the assemblies are in See About the Status and Log Screens on page 2 52 Log Screen From this screen the feedback codes from the machine See About the Status and Log Screens on page 2 52 ...

Page 61: ...chines is displayed The machines are constantly polled feeding back their state of operation This feed back is a great tool to instantly view the status of each machine This information can be used to troubleshoot any issues that may occur Select the tabs to jump to associated Operator s Screen The active screen will highlight with a green background ...

Page 62: ...copied or deleted directly at the Operator s Station Select the Libraries Tab to jump to these screens About The Door Job Library And Template Library Lists Select the corresponding tab to jump to each list Each screen has a table listing the name of the Door Job Template a description date created and date modified At the bottom of the screen is a count of the door jobs templates in the table and...

Page 63: ...loading G Code Edit View Button Select a Template or Door Job Either Edit a known Job Template or use existing to run doors Jumps to the Job Creation Screen Most Common Pathway to start the door Machining Pro cess Clone Button Select a Template or Door Job from the list to copy and rename Delete Button Select a Template or Door Job from the list to Delete Job Creation Screen FIGURE 2 4 Screen Shot...

Page 64: ...r Data Menu View edit or create the door parameters to be processed Door Parameters Displays the basic parameters of the door being processed If creating a door enter the parameters Door Hand Select the Hand Ori entation of the Door From the drip down menu select Left Hand Right Hand Left Hand Reversed Right Hand Reversed Door Material Select type of material of the Face Hinge side and Lock side o...

Page 65: ...he Plate Cut Feature Group Top level of the door cut Contains the Child Fea tures Add Group Select to create a new Group Features can be created in the Features Details Menu Add Child Select to create a new child to a group or child Add from Library Select to add a tem plate from the Tem plate Library Delete Select to delete a Group or Child Notes Indicators next to the Child Features are color co...

Page 66: ...e Feature Group Location Add Remove Edit the Select the location of the Group Cut Feature Name Name of The Fea ture Under the Group Feature Type Select type of cut Circle Hinge Rectangle TeeShape GCode Door Side Select Door Side Lock Edge Hinge Edge Top End Bottom End Features are created by adding children to a feature group All features are specific cuts that can be made on a door Feature Types ...

Page 67: ...tes are valid Save Select to Save all a new Door Job or save Edits to a Job Password Pro tected Add to Queue and Door Qty The first step of door processing Enter the quantity of doors to be processed and then select the Add to Queue button to start the process See Machine Start Summary on page 2 19 About the Libraries Screen KVAL Operation Service Manual 2 32 ...

Page 68: ...nities to edit or verify the pro cess Display Area Door Axis Door Orientation Preview Surface Bottom End Top End Hinge Edge Lock Edge Hinge Pivot Face Opposite Pivot Face Color Coded Grid Lines in Change the size of the grid line Scale Percent Dis plays the magnifi cation value of the screen preview Note May use the mouse wheel to zoom in and out Grid Lines ON Select to toggle Line or and OFF Abou...

Page 69: ...ises The figure below represents the color coding of door orientation in the Job Preview Screen T Thickness L Length W Width Key Lock Edge Bottom End Hinge Edge Hinge Pivot Face Opposite Pivot Face Top End Opposite Key Face Opposite Hinge Pivot Edge Hinge Pivot Face Edge Key Face ...

Page 70: ... line Select the Machine Line Tab on the left side of the screen to jump to this screen This includes Menu Description Machine Activity For each machine a table shows job name quantity of remaining doors doors being processed and status of the machine Queued Jobs shows a list of the upcoming jobs Line Controls Common operations to control the machine line Machine Line Screen ...

Page 71: ...achine Lists the machines in the line Status Lists the status of each machine Quantity Lists the quantity of doors at the start of the Door Job Job Lists the name of the Job being processed The Job name reflects the name assigned in the Door Job Library Remaining Lists remaining quantity of doors left in the Door Job Templates Template file bing utilizes About the Machine Line Screen KVAL Operatio...

Page 72: ...e jobs that are going to be processed Commands Select the Remove button to clear the Job from the list Creation Time List the time when the job is put in queue Job List the name of the Job Quantity Lists the quantity of doors at the start of the Door Job About the Machine Line Screen 2 37 KVAL Operation Service Manual ...

Page 73: ...N The door will automat ically feed through each machine Auto Feed OFF The feed status must be set the machine Operator s Screen Clear Queued Jobs Press to clear the entire list of door jobs in the Queued Job table Home the Machine Line Press to Home every machine in the line Reset the Machine Line Press to reset the every machine in the line You Must Home the line after this reset is performed Ab...

Page 74: ...ed controls for the Machine This section Manual Servo Control Operate the machine manually by moving the servo motors See page 2 46 Tool Path Preview Observe the path of the tool during machining process See page 2 45 Calibration Description and instructions to fine tune the servo drives See Chapter 3 Tool Config Fine tune the tools parameters for an accurate cut See page 2 50 Status For informati...

Page 75: ...set the machine to the start position Important Press the Home button after resetting the machine Setup Mode On Off Select Setup Mode to toggle on or off In the On mode a safe mode is active The machine will go through normal sequences except the cutting motors will be inactive Use this mode to check the machine operation without making a cut on the door With the setup mode set to on the button wi...

Page 76: ...tion This button also allows the opportunity to repeat the selected cut This control is also located at the machine control panel as a mechanical switch but ton Door Finished Clears the job if user wants to finish the job before completing all cuts or at the end of the job if Auto Feed out is disabled If the machine is working on the last side and Auto Feedout is enabled a light will illuminate on...

Page 77: ...ob is loaded in the machine Enable Feeler Adjust Press to Enable or Disable the Feelers If this button is Disabled the door measurements will be derived from the Door Job specifications May be used to verify a door against the feeler measurement About the Edge SS Interface Screens KVAL Operation Service Manual 2 42 ...

Page 78: ...SS Manual Control Screen About the Edge SS Feeler Servo Controls These controls operate the Thickness Feeler The feeler uses encoder technology to accu rately measure the thickness of a door For information about the Feeler see About the Door Length Feeler on page 6 8 LengthFeelerEncoder Dis plays the Count Position of the Feeler Encoder Feeler Forward Press and Hold to move the feeler forward Tow...

Page 79: ...om the Door Cut Z Forward Towards the Door Cut X Forward X Reverse To the Stacker Position of Encoder About the Edge SS Head Servo Controls The manual controls are designated by X Y and Z axises for the Main Head Press and hold the button Forward or Reverse to move the head in the desired direction About the Edge SS Manual Servo Control Tab KVAL Operation Service Manual 2 44 ...

Page 80: ...brary of the Edge SS can be viewed This sequence can be essential if troubleshooting calibrating or checking the wear of a tool Dis crepancies can be viewed before cutting into a door saving product and time The figure below displays a sample of a good Deep Mortise Cut 1 Select a G Code routine form the drop down menu 2 Select the Render Button 3 View the path of the tool on the screen Step 1 Step...

Page 81: ...chine General Operating Controls The Tool Config Screen contains a sample of the following List of the available tools Pop up menus to enter information about each tool Specifications The ability to adjust the method of chisel operation during machining The ability to enable or disable specific tool slots The ability to name the tools to familiar names The ability to lock and unlock the ability to...

Page 82: ... 1 Select Unlock 2 Enter Password Click OK 3 Ready to Enter Data About the Tool Pop up Screens Each tool slot has versatility to choose between entering router or chisel information Click the Enable Check Box to clear the box and disable the tool Below are samples of the pop up windows available Drill Pop up Drill Pop up Disabled About the Tool Pop up Screens Sample Drill Configuration Pop Ups Dri...

Page 83: ...op up Disabled Sample bout Tool Locations Edge SS Tool locations are identified by slots See the figures below for the locations and identifications Note Below are factory suggested locations Identification of Slots can be altered through this menu Tool Slot 4 Tool Slot 2 Tool Slot 3 Tool Slot 1 Tool Slot 6 Tool Slot 5 Edge SS ...

Page 84: ...entified by slots See the figures below for the locations and identifications Note Below are factory suggested locations Identification of Slot and location of chisel can be altered through this menu Rectangle Orientation Lower Left Chisel Lower Right Chisel Upper Left Chisel Upper Right Chisel Vertical Orientation ...

Page 85: ... should match in type and specifications 3 Enter the data into the pop up screen Router or Drill Measuring Tool Length 1 Measure the parameters listed below Total Tool Length The distance from the collet face to the tool s tip Tool Cutting Length The distance from start of the cutting area to the tip of the bit Tool Point Length From the point where the point starts to the end of the bit 2 Update ...

Page 86: ...ntering Data into the Pop up Menu Insert specifications of the tools being used to make the cuts Ability to name the tools to user defined descriptions Customize the tools to reflect the actual tool parameters making the most accurate cuts Ability to define cut operation ...

Page 87: ...sent to Service Support if any issues occur About the Status Screen From this screen real time feedback during the operation of the machine can be viewed The feedback includes times dates and machine status Status includes a True flag if the assembly is in operation or a False flag if not in operation Also status can include data and motor states idle operation The data can be filtered to observe ...

Page 88: ... error code to machine sections or functions The top line will have the most current routine that is running The codes are color coded Red Error Green Report is a non issue Yellow Warning If the machine issue can not be resolved call KVAL Inc 1 800 553 5825 Have any error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten down time FIGURE 2 7 ...

Page 89: ...nch out All Feature Groups have their own L T and W location that is separate from the features contained inside This allows the user to quickly move templates to new locations or to duplicate templates in multiple locations by adding new locations to the group Feature Group Name This field is required when saving a new template Feature Features are created by adding children to a feature group Al...

Page 90: ...Red only appears if the expression cannot be interpreted to a real number for validation while orange appears if the line cannot perform the cut Validation Report Validation will only work if the information that is fed to the machine line is accu rate Inaccurate information that is downloaded from Tool Configurations Calibra tions or Libraries e g material types will produce unexpected or potenti...

Page 91: ...Definitions KVAL Operation Service Manual 2 56 ...

Page 92: ... Section Name Summary Page About Calibration Descriptions of the Calibration Menus Tips to look for before calibrating page 3 2 About the Calibration Tabs Descriptions of the Calibration Tabs page 3 3 How to Enter Calibration Data Descriptions of how to use the calibration screens page 3 6 About the Edge SS Calibration Screen Descriptions of the calibration available page 3 7 ...

Page 93: ...tion Reference Cut delivers a calibration cut for the Hinge Heads and for the Lock Head Use the Calibration Menus to adjust the tool sets from information taken from the calibra tion cuts 1 Hinge Cut Performs a cut to verify the Predrill Hinge Router and the Counter Rotate Router 2 Lock Cut Performs a cut to verify the Predrill Counter Rotate Router Plunge Router Plate Router and the Deep Mortise ...

Page 94: ... reporting Finding errors from these screens will help localize problem areas Note If the machine issues 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 See Getting Help from KVAL on page 1 17 Access to the Calibration Adjustments Buttons to unlock access to calibrati...

Page 95: ...Locked to a green Calibration is Unlocked 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 door cut second finger and thumb at right angle to each other The first finger represents the positive direction of the Z axis the thumb represen...

Page 96: ...ation Tabs 3 5 KVAL Operation Service Manual Axis Direction for the Edge SS Front Section Y X Axis Positive movement Z Axis Positive movement Y Axis Positive movement Z X Y Z X FIGURE 3 10 Left Hand Rule Front Section ...

Page 97: ... 800 553 5825 See Getting Help from KVAL on page 1 17 2 Enter the offset positive or negative number in the white box below the Offset title to adjust the servos in the X Y and Z directions 3 The Base display box keeps a running total of data entered to help keep track of the changes 4 The Combine button merges the offset number to the base to adjust the servo 5 Click the Save button to store the ...

Page 98: ...s a list of calibration adjustments Select the Edge SS Tab located on the left hand side of the machine then select the Calibration Tab to jump to this menu Enter adjustments according to Axis Direction for the Edge SS Front Section on page 3 5 and How to Enter Calibration Data on page 3 6 Ensure Calibration is unlocked Edge SS Calibration Screen ...

Page 99: ... 2 Ensure the Set Up Mode is Enabled no cut ting a Select the Edge SS Main Control Tab and under the Main Control Section select the Setup Mode button 3 Feed a Test Door into the machine 4 After the door has been fed in Check the measurements fed back from the encoders a Select the Log Tab from the Edge SS Screen check the latest feedback from encoder 5 Get averages of the feedback Capture the mea...

Page 100: ...iage heads to match to the cal ibration list Hinge Head FIGURE 3 11 Carriage Designators Using the Carriage Axes Calibrations The Carriage Axes calibration treats the entire tool set within the carriage as one unit There fore if all parameters or a particular cut are out of specifications use this calibration adjustment 1 Identify the cut out of spec ification 2 Select Carriage A 3 Measure the cut...

Page 101: ...e down direction Y Offset X Offset Y Offset X Offset Note Reference is looking directly at the cut using the Left Hand Rule Calibrating the Feelers 3 10 KVAL Operation Service Manual About Tools Calibration With the Tools Calibration each tool assembly within the Head can be adjusted individually The tools are identified with a slot number axis or diameter of tool and the customer assigned name Ch...

Page 102: ...fully loaded Cutter Head Options may vary however the tool slot designators will have the same locations Tool Location Parameter Tool Slot 1 Axis Y Axis X Axis Z Diameter Offset Tool Slot 2 Tool Slot 3 Tool Slot 4 Tool Slot 5 Tool Slot 6 Axis Y Axis X Axis Z Chisels Axis Y Axis X and Axis Z of each discrete corner Tool Slot 4 Tool Slot 2 Tool Slot 3 Tool Slot 1 Tool Slot 6 ...

Page 103: ...ool Slot 5 Calibrating the Feelers 3 12 KVAL Operation Service Manual Chisel Locations Rectangle Orientation Lower Left Chisel Lower Right Chisel Upper Left Chisel Upper Right Chisel Vertical Orientation ...

Page 104: ...djustments Below are simplified examples of how the cut will change with calibration Y Offset X Offset In this case the router pocket is out of specifica tion Negative offsets should be entered into the Y and X axis calibration to bring into specifica tion If there are any issues with lip depth use the Z axis calibration positive number to increase depth negative number to decrease depth In this c...

Page 105: ...The chisel calibrations adjust each corner of the square cut pocket For more information see Chisel Locations on page 3 12 Using the Tools Calibration 3 14 KVAL Operation Service Manual ...

Page 106: ...can remotely help troubleshoot your machine Chapter 4 at a Glance Section Name Summary Page System IT Administration This section describes the basic parts of the operation of the PLC in the machine Such as About the PLC Connections on the PLC Backing up the Computer About Remote Connection to KVAL Service page 4 2 Updating Door Template Files This section describes the process of updating G code ...

Page 107: ...Beckhoff CPU module as a PLC Programmable Logic Controller In addition to the CPU and the chipset the module also contains internal main memory The com puter has a removable Compact Flash card from which it boots Each controller utilize a Win dows based operating system with TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include A smart power supply to ...

Page 108: ...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 folder for the most current date This folder should he labeled Year Month Day 3 Copy it onto a server or Hard drive and store it for possibly a future day 4 Backup to a thumb drive or other storage device About Remote Connect...

Page 109: ...System IT Administration 4 4 KVAL Operation Service Manual ...

Page 110: ...nce is broken into machine cycle times and describes the suggested mainte nance steps to perform 300 Cycles 600 Cycles 3 000 Cycles 12 000 Cycles 72 000 Cycles page 5 2 Tool Changing Schedule Describes the suggested time frame to change the tools in the machine page 5 13 Lubrication Requirements This section describes the lubrication requirements for the machine including types of lube to use This...

Page 111: ...teps may not pertain to all machines Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tagout or lockout the electrical and air pressure systems This should be done in accor dance with applicable state and or federal code requirements To view a video of the maintenance process visit the KVAL website Select the Video Tab to view videos http www ...

Page 112: ...n 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 with dry silicone spray Lubricate Lubricate all bearing shafts...

Page 113: ...t and grime build up can cause issues with the operation of the machine Use pressured air to blow off dust and debris on entire machine Use a clean rag to clean areas not affected by pressurized air Also blow out any dust collection units Check vertical bearings for loose screws Loose screws could cause bearing damage High Dust Accumulation Areas ...

Page 114: ...ure Gages Adjust if nec essary to the proper PSI located on the label Adjust only if Trained in Maintenance Inspect Air Filter Water Traps Empty trap if necessary Slide locking switch down to unlock twist trap to remove Reverse action when installing trap Inspect Tooling Inspect the Tooling for wear Drill Bits Cutting Tools See How to Access to Bit Assemblies on page 5 24 ...

Page 115: ... one on the opera tor s station Lift up and pull bottom out Remove screw and slide up Empty Dust Collection Units Check and empty any dust collection units Clean any dust filters Dust collection systems vary from machine to machine Follow manufacturers directions to empty dust collection units Filters Dust Collection Containers FIGURE 5 2 Typical Dust Collection Unit ...

Page 116: ...sson ing traction on door Check belts for slickness or door slippage Inspect all Photo Eyes Inspect all photo eyes secure and tight Check Connection to Photo Eye Check Nut that attaches Photo Eye to Machine Inspect Limit Switches Inspect all limit switch arms for tightness or breaks Inspect the switch for cracks in the body and check that the switch arm actuates clicking sound when moved to the ex...

Page 117: ...assem blies air valves and hoses Check from source to end assembly Check Hoses for kinks and rubbing manifold connections and Air Cylinder connections Refill Lubricators 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 installin...

Page 118: ... Grease ball screw bearings if applicable For a table of lubrication types to use Lubrication Schedule For locations to lubricate See Grease Ball Screw Bearings Clean Bearing Shafts Clean all bearing shafts with clean dry cloth Spray shaft with silicone oil and clean build up grime and dirt ...

Page 119: ... over time of use Check for chain stiffness Stiff chains do not provide a tight fit over the gears Inspect Air Cylinders Inspect all air cylinders for air leaks Replace the cylinder if seal is leaking Symptoms include a cylinder not extracting or retracting to the limits Cylinders not holding their position Inspect Hydraulic Lines Inspect hydraulic lines for loose fittings leaks and cracks Inspect...

Page 120: ...Service Manual Inspect Ball Rail Shafts Inspect ball rail shafts for pitting or abrasions Example of a Pitted Ball Rail Clean and Lubricate Slides Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray ...

Page 121: ...ransition with a door feeding into and out of machine Feed door in and out to verify smooth tran sition is repeatable Electrical Check all connections in each node box and electrical panel Wires may become loose due to vibration Check contactors for wear Computer Backup Backup computer software Wash Filter and Lubricator Bowls Wash filter and lubricator bowls with soapy water Slide lock down to un...

Page 122: ...e 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 123: ... 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 Shell Tellus32 Gulf Harmony 32 Gear Box Recommended...

Page 124: ... the fitting so that it can be wiped clean to reduce the amount of debris carried with the grease into the bearing Note Bearings without grease fittings have been pre lubri cated at the factory and do not require further lubrica tion Note Make sure to clean excess grease to avoid contact with feed belts clamping areas or the door Zerk Fitting Pillow Block Bearing Housings A pillow block is any mou...

Page 125: ...reliable operation Greasing Flange Bearing Bearing Housings Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 250 hours of operation Lip FIGURE 5 4 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 Gre...

Page 126: ... such an asset that the bearing blocks often require little maintenance for the life of the machine Greasing ONCE A YEAR Cross Section of Tapered Bearing Tapered Bearing FIGURE 5 6 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 an...

Page 127: ... pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 80 hours of operation Ball Screw Nut Housing Ball Screw Drive Greasing Ball Screw Nut FIGURE 5 8 Example of 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 Servo Motor Tapered Bearing Housing ...

Page 128: ...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 129: ... follow the Lock Out Tag Out procedures Caution Servo Motor Drive Assembly Locations Edge SS Identify zerk fittings and apply EP 2 grease Find the X Y and Z axis rails to identify bearings Some bearings may be difficult to get access to Use an extender to reach tight areas Make sure that Lockout Tagout has been performed before maintenance For recommended greasing sched ule see Ball Screw Drive As...

Page 130: ...Some bearings may be difficult to get access to Use an extender to reach tight areas Make sure that Lockout Tagout has been performed before maintenance EP 2 Grease FIGURE 5 11 Cutting Head Bearing Locations Deep Drill Bearing Locations Option Identify zerk fittings and apply EP 2 grease Find the X Y and Z axis rails to identify bearings Some bearings may be difficult to get access to Use an exten...

Page 131: ... delivers the lubricated air to valve banks and air cylinders Shop Air Input Air On Off Muffler Filter purge Pressure Gauge with adjust Clean Dry Air CDA to Air Blow Off Lubricator Lubricated Air Output FIGURE 5 13 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 obser...

Page 132: ...rmony 32 To prime the lubricator find an air line on the carriage section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose Repeat this same procedure for the back section and other trouble areas It is recommended to check t...

Page 133: ... edge Tool Length The distance from the collet face to the tip of the bit 3 Compare these measurements to the data in the Tool Setup Group in the Calibrate Machine Screen This screen is accessed by the Setup Button 4 Update the data in the Tool Setup Group see Chap ter 2 of the Operation Manual Important The accuracy of the data Tool Setup Group is important Any errors could damage tooling or prod...

Page 134: ...lies 5 25 KVAL Operation Service Manual FIGURE 5 15 Removing Pre Drill or Router Bit Inspect Collet 2 Inspect and clean collet assembly Collet Spindle Collet Nut Verify that there is no damage or bluing on the side of the collet FIGURE 5 16 Collet Assembly ...

Page 135: ...r machine parts At Least 1 8 Clearance 3 Lightly attach collet assembly on drill 4 Insert the new bit into the assembly 5 Before tightening the collet assembly adjust the bit depth to the measurement taken in step 1 Ensure there is a minimum of 1 8 clearance from the end of the bit to the bottom of the tool holder 6 Tighten the collet assembly 7 Inspect and verify the work Clean the work area ...

Page 136: ...th chisels Chisel Orientation on Machine Some machines have a rectangle orientation or a vertical orientation Below are samples of each Rectangle Orientation Lower Left Chisel Lower Right Chisel Upper Left Chisel Upper Right Chisel Vertical Orientation Sample is taken from a Face SS Sample is taken from an Edge SS ...

Page 137: ...ss the chisels Important Be alert that all tools in the assembly are sharp and can cause injury 4 Using a 7 16 wrench loosen and remove the bolts retaining the chisel clamps Remove the clamp and chisel Clamp Chisel 5 Clean off any particulate that may have accumulated on the clamp and chisel area This is especially important for the lower tools where particulate can get trapped on the tool surface...

Page 138: ...rease pressure to push the oil out The lubricator well sends a replacement alert to the user screen when oil is low 5 The alert is a 30 day warning but it is recommended to change it as soon as possible Refer to Electrical Drawing for connections labels X Axis Motor X Axis Gear X Axis Gear Applicator Hose Connection Female Connector Lubricator Well Bracket Sensor Hose Connection Male Location In F...

Page 139: ... to the X axis motor gear and gear applicator by removing the grate below the heads 3 If needed cut the hose included in the kit to match the one on the machine 4 Attach the 2 hose connectors to the ends of the new hose 5 On the new lubricator well set the dip switches Remove the protective top from lubri cator well Dip switch is located on the top Set the number 5 switch to the ON position This s...

Page 140: ... and the applicator 11 Bracket the new well against the machine 12 Slide the black and red wires into the connector Secure with a small screw driver 13 Polarity is not an issue but for consistency replace wires as they were 14 Route sensor wires to the corresponding node and connect to the correct terminals 15 After lubricator well is secured on machine perform a test run 16 Verify the oil is bein...

Page 141: ...lues 5 32 KVAL Operation Service Manual Collet Torque Values KVAL recommends torquing the collets Torquing adds consistency is important for repeatable machining Follow the torque tool manufacturers method of torquing ...

Page 142: ...Collet Torque Values 5 33 KVAL Operation Service Manual ...

Page 143: ...Troubleshooting Electrical Problems 6 30 KVAL Operation Service Manual ...

Page 144: ...ion is available in this chapter Section Name Summary Page Troubleshooting Basics This section includes basic troubleshooting infor mation Includes analyzing sub systems to desig nate a starting point for troubleshooting page 6 2 About Motion Control This section contains basic information on the operation of motion control circuits Includes dia grams of the control circuits page 6 4 Describing Co...

Page 145: ...n Is the router not cutting Is the cut out of specification Verify Verify or analyze the subsystem assembly that is responsible for the issue For example How is the subsystem supposed to work What is keeping the subsystem from working Before you Adjust Sometimes simple problems can seem to be complex issues Before making adjustments check for the following common issues 1 Is the loaded setup corre...

Page 146: ...on ing Cutter Power 4 Unclamp the Door Door Clamp 5 Move Door Out Feed System 6 Wait for Next Door Feed System Basic Troubleshooting Steps Determine Where The Sequence Step Where the Failure Occurs What was the Machine Trying to Do What Was the Machine Trying to Do Next Check the Sequences in the Table Below How is the Broken Section Suppose to Work What is Keeping the Broken Section From Working ...

Page 147: ...words are the correct photo eyes limit switches or ferrous sensors activated Check the con troller inputs to insure the proper sensors are activated If the controller is a PLC an activated input is lit Some touch screens have inputs status also 3 Common Position Feedback failures Photo Eye Bad element or bad cable Limit Switch Stuck or failure Wiring Broken worn insulation PLC Bad input port 4 Che...

Page 148: ... out 6 Wait for the next door Point to Point Point to point motion control involves moving a load from one fixed position to another fixed position at a constant speed and along one line axis X Y or Z A typical point to point would be a drill with a fixed depth The drill is either retracted or extended using a pneumatic cylinder Typically the drills travel is limited by physical stops Incremental ...

Page 149: ...between the humans and the machine Examples A touch screen a PC or a button panel The Controller Translates entered information into a form the positioning system can understand Listens to the machine s other subsystems waiting for the OK to move command Sends the positioning instructions to the positioning system Listens to the positioning system for position status if there is a feedback loop Te...

Page 150: ...e may cause personnel injury or death Troubleshooting checks must be performed by a Qualified Electrical Technician PLC Output Fuse s Line Voltage Power Contactor Control Coil Input Power Input Power Output Control Circuit Common ON Should measure Control Voltage 120 VAC here Should measure Line Voltage here Should measure Line Voltage here Line Voltage here Should measure Relay 120 VAC DC Should ...

Page 151: ...as a trigger to check the circuit See Troubleshooting with the Status Light Panel on page 6 25 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 ...

Page 152: ...ooting checks must be performed by a Qualified Electrical Technician Common Motor Drive Control PLC Output Fuse s Line Voltage Motor Power Motor Power Input Output Power Control Circuit Common ON Measure Control Voltage 24 VDC here Measure Line Voltage here Measure Line Voltage here ON Drive STF Forward RL STR Revers 2 SD COMMON OFF OFF OFF Run 300 Run Light should be ON Displays the Motor Frequen...

Page 153: ...diagram see Figure 6 22 on page 6 9 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 purposes Fault Errors will b...

Page 154: ...e lit To reset a VFD 1 Push lighted button to reset the indicated motor b If the button light turns off continue with production c If the button stays lit identify the motor by way of the label on the button turn off that function at the switch panel Check the corresponding output on the PLC output If the output is on it will not let the motor reset Dis connect the output wire and verify that the ...

Page 155: ...re Air Cylinder Common Control Circuit ON Measure 24 VDC here Control Voltage Should have High Pressure air here Cylinder Control Control Coil Input Air Input Air Output Valve Should have High Pressure air on Activated Output Schematic Drawing of Pneumatic Circuit Note Pre 2006 machines may not contain the 24 Volt relay 120 Vac is directly fed into the Control Coil Check the input circuitry to the...

Page 156: ...t 24V from PLC to open a port FIGURE 6 26 Typical Pneumatic Assembly About the Coil Solenoid The Solenoids are connected to the top of the manifold Labels indicating their function and PLC connections are attached to the solenoid body Use this information to troubleshoot system if nec essary Solenoid type will vary with machine application Common controls include an operational LED and Manual oper...

Page 157: ...is delivered to port B FIGURE 6 28 Cross section of Air Cylinder How the Pneumatic System Works The Pneumatic system consists of a brain PLC an action Positioning System and a result Moving the Load For a generalized representative this section describes 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...

Page 158: ...24 V Applied Router Assembly Load Position Feed Back Air In Control Valve Extend Sensor Activated Air Pressure Extends Cylinder and Router Assembly EXTENDED Retract Process If the PLC determines the conditions are right to retract the Router 1 The Control Valve directs compressed air to the retract port of the Cylinder 2 The Cylinder and Router retract deactivating the Extend Sensor 3 When the Cyl...

Page 159: ...otice about Adjusting Cylinder Speed Do not adjust the cylinders to speed up production The air cylinder timing is part of a well tuned system of electronics programming and mechanics Adjustment of the cylinders for speed can cause unsatisfactory results in feed and out feed problems far marks in the corners of hinge pockets and flipping screws in Hoppers However sometimes machine settling mechani...

Page 160: ...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 161: ...ls on the solenoids identify loads they control Location of Valve Banks on the Edge SS Table Valve Bank 2 Table Valve Bank 1 Cutter Head Valve Bank Deep Drill Valve Bank FIGURE 6 29 Location of Valve Banks The table below lists the typical loads controlled by the valve banks Note The values in this table are typical To verify check the labels on the solenoids and the air schematic TABLE 6 2 Valve ...

Page 162: ...ons are made to coupler interfaces located near the sections they control See your machine s schematic package for detailed wiring information Connections to Servo Drives The Servo Drives are located in the Main Electrical Panel The outputs connect to the servo motors of carious assemblies They may include the Head X Y and Z motors feed motors back section location X Y and Z motors For detailed wi...

Page 163: ...ine The motors interact with the Template PLC and servo drivers They are highly accurate in movement and position The motors are part of the calibration of the machine See the calibration chapter for axis direction X Axis Servo Motor Y Axis Servo Motor Z Axis Servo Motor Deep Drill Z Axis Servo Motor Feeler Servo Motor FIGURE 6 31 Location of Servo Motors ...

Page 164: ...oto Eye 0VDC is sent to the PLC As a result any of the photo detectors output equals 0VDC when a door is sensed Some detectors have an emitter and receiver built in one unit such as an in feed sensor where a door blocks the light and reflects back to the unit Some detectors have an emitter and receiver built in separate units such as the through beam sensor set at a distance from each other If an ...

Page 165: ...Switch Arm Using Sensors to Trouble Shoot Photo Sensors often get dirty Make sure they are clean If they are not clean debris may block the signal or provide a false 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 The distance from an eye...

Page 166: ... checked Exit Click to close the running Kval Cam program Backup Logs Click to save the to save all data from the machine operation Notes may be added to describe the saved file Backup and Export Click to send machine data to a text file The file may be sent to Service Support if any issues occur Notes may be added to describe the saved file Build Info Click to view upper level notes about the cur...

Page 167: ...nes have signals on the computer that light up when the input or out put functions are energized respectively Computer controlled as well as non computer controlled machines have white 120V control power terminal strips This will indicate power supply from the respective circuits PLC controllers also have lights on them for the input and output functions You can easily find out which circuits are ...

Page 168: ...spective sensor Check the Status Light Panel If all lights are observed there are no overloads or emergency stops tripped See Troubleshooting with the Status Light Panel below for more information Note Most electrical problems are related to mechanical malfunction e g stuck motors jammed chain blocked photo sensors etc Note If a solenoid valve is suspected and not cleared in the air checks section...

Page 169: ...w to isolate the cause NOTE Be sure to proceed down the table starting with the CONTROL POWER light STEP 1 Control Power Amber If light is OFF go to item A on page 6 27 STEP 2 Overload Relay Amber If light is OFF go to item B on page 6 28 STEP 3 E Stop Amber If light is OFF go to item C on page 6 28 STEP 4 Stop Amber If light is OFF go to item D on page 6 28 STEP 5 Start Amber If light is OFF go t...

Page 170: ... 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 the fuses at the Fuse Block and the contacts on the Control Transformer ...

Page 171: ...cal Problems 6 28 KVAL Operation Service Manual E Stop Light OFF Check to see the if any E Stop buttons are pulled out NOTE Location and quantity of E Stop buttons var ies 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 172: ...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 power supply Check for 24VDC at between any DC and DC terminal on the ...

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Page 174: ...ty2 33 collet assembly inspection5 23 computer as a PLC4 2 backing up4 2 4 3 contact information1 2 control panel light not on troubleshoot6 24 control power indicator light description2 10 control transformer switch power up2 7 2 9 2 11 customer service1 2 D Door Length Feelers description of2 4 drill bit replacing5 19 dura lith grease bearing lube5 15 DVI USB module location4 2 E emergency shutd...

Page 175: ...rn procedure1 14 programmable logic controller PLC4 2 R remote operation setting up machine for1 16 reset machine button description user interface2 33 Restore Points create load delete3 5 return material authorization RMA 1 14 returning the product to Kval1 14 Right Hand Rule3 4 router bit replacing5 19 Routine Speed Percent2 35 S Safe Mode Enabled Disabled2 33 safety guidelines1 5 Safety Sign Of...

Page 176: ...10 Toggle Clamp2 35 Toggle Stop2 35 troubleshooting using status lights6 23 TwinCAT 2 software automation software4 2 U USB module4 2 W Windows CE operating system about4 2 Z zerk fittings5 16 locations5 16 zero energy start up clean up1 12 inspect1 12 ...

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Page 180: ...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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