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Operator’s Tour

2-2

KVAL EP-1 Operation/Service Manual

Operator’s Tour

This section takes you on a tour of the

EP-1

machine. The figure below shows locations of

selected areas, parts, and assemblies on the machine

Foot Pedals

Air Bank

Drill

Cutting

Head

Factory

Air Input

Electrical

Panel

.

FIGURE 2- 1.

Top View of the EP-1

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Summary of Contents for EP-1

Page 1: ...Innovation Quality Honesty Operation and Service Manual Published 1 23 15 EP 1 Edge Prep Machine ...

Page 2: ...rademarks 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 Incorporat...

Page 3: ...ser 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 above...

Page 4: ...KVAL EP 1 Operation Service Manual ...

Page 5: ...g State 1 10 Getting Help from KVAL 1 12 On Line Help 1 12 Product Return Procedure 1 12 Safety Sign Off Sheet 1 15 A Note to the Operator 1 15 Chapter 2 Operation of the EP 1 Operator s Tour 2 2 About the Electrical Panel 2 5 Description of the Six Light Panel 2 6 Quick Start 2 7 Setup of the EP 1 2 8 Setting the 0 and 3 Bevels 2 8 Setting a 2 3 4 or a 2 3 8 Backset 2 9 Setting the Face Plate Rou...

Page 6: ...r Input System 3 5 Adjusting the Air Line Lubricator 3 5 Priming the Air Line Lubricator 3 6 Chapter 4 Trouble Shooting the EP 1 Adjusting Limit Switches 4 2 Adjusting the Bolts on the Face Plate Turrets 4 3 Troubleshooting Electrical Problems 4 4 If the Power Stops During Normal Operation 4 4 Troubleshooting with the Status Light Panel 4 5 Troubleshooting the Air Cylinders 4 10 Adjusting Cylinder...

Page 7: ...he EP 1 1 2 About this Manual 1 2 Safety First 1 3 Safety Sheet Sign Off Sheet 1 3 Safety Terminology of Labels 1 3 Safety Guidelines 1 3 Lockout Tagout Procedure 1 7 Follow the P R O P E R lockout rule of thumb 1 9 Zero Energy to Start Up 1 10 Zero Energy State to Start Up to Operating State 1 10 Getting Help from KVAL 1 12 On Line Help 1 12 Product Return Procedure 1 12 Safety Sign Off Sheet 1 1...

Page 8: ...e It uses lock holes bored by previous machinery as an index About this Manual This Manual is includes identification of machine assemblies power up and power down steps operation and using the user interface The Manual also includes maintenance and troubleshooting information TABLE 1 Title Part Number EP 1 Operation and Service Manual 83_OPSRV_EP1_V1 ...

Page 9: ...ogy 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 t...

Page 10: ...s 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 m...

Page 11: ...upply 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 ...

Page 12: ...chine 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 P...

Page 13: ...s etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shut down 3 Obtain locks keys and tags from your employer s lockout center 4 Disconnect power a Turn the disconnect switches on the main electrical panel to the OFF position Then pull out the red tab and place a padlock through the hole Place your tag on the padlock as per the tagout guidelines below see illustra...

Page 14: ...ty devices are installed 8 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 9 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 10 The tags must be destroyed and the locks and keys returned to the lockout center Lo...

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

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

Page 17: ...t procedures work because you are the only one with the key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect ...

Page 18: ... Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday On Line Help On machines with a Beckhoff PLC and an internet connection our service team are able to con nect run and troubleshoot your machine Ask about this procedure when calling are service team See Chapter 3 System IT Administration on page 3 1 for more information Product R...

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

Page 20: ...Getting Help from KVAL 1 14 KVAL EP 1 Operation Service Manual Page Intentionally Left Blank ...

Page 21: ...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 elect...

Page 22: ...Safety Sign Off Sheet 1 16 KVAL EP 1 Operation Service Manual ...

Page 23: ...nce Operator s Tour 2 2 About the Electrical Panel 2 5 Description of the Six Light Panel 2 6 Quick Start 2 7 Setup of the EP 1 2 8 Setting the 0 and 3 Bevels 2 8 Setting a 2 3 4 or a 2 3 8 Backset 2 9 Setting the Face Plate Router for Vertical Travel 2 10 Setting the Router Depth 2 10 Powering the EP 1 2 12 How to Power Up the EP 1 2 12 Machining a Door 2 13 Move Door into Position and Start Sequ...

Page 24: ...rator s Tour This section takes you on a tour of the EP 1 machine The figure below shows locations of selected areas parts and assemblies on the machine Foot Pedals Air Bank Drill Cutting Head Factory Air Input Electrical Panel FIGURE 2 1 Top View of the EP 1 ...

Page 25: ...L EP 1 Operation Service Manual Figure 2 2 below shows select EP 1 front section assemblies and controls Control Panel Clamp Cone Clamp Foot Pedals Cone Alignment Door Clamp Start Sequence Router FIGURE 2 2 Front Section View ...

Page 26: ...AL EP 1 Operation Service Manual Figure 2 3 below shows a isolated view of the drill and router placement Caution Never reach your hands into this area unless the motors have stopped Drill Router FIGURE 2 3 Drill and Router ...

Page 27: ...Drive to interact with the router motor Warning High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off If working on the panel follow safety pro tocol as described in Chapter 1 Supplies voltage to drill by way of the contactor and thermal overload circuit Main Electrical Panel High Voltage Input Fuse Bank F1 F8 Router VFD Drill Thermal Over load Rela...

Page 28: ... 4 Stop 5 Start 6 24VDC Control Power light illuminates when the Control Transformer is pulled out and the power is working on secondary side of transformer Overload Relay The overload circuit is working when light is on E Stop The back gate is closed and Frame E stop is not activated when this light is on 24VDC light comes on once the ACR is latch and the 24VDC power Supply is working Stop This l...

Page 29: ...ent at machine and the DL NCD main air supply valve is turned on 1 Setup EP 1 See Setup of the EP 1 on page 2 8 2 Power up the EP 1 See How to Power Up the EP 1 on page 2 12 3 Running a Door See Machining a Door on page 2 13 4 Power down the EP 1 See How to Power Down the EP 1 on page 2 15 ...

Page 30: ...4 or a 2 3 8 Backset Adjust the Face Plate Length Vertical turrets x2 Adjust the Router Depth for 0 or 3 Setting the 0 and 3 Bevels 1 To set the Zero and Three degree adjustment locate the two adjustments on the front section of the machine The top knobs adjust the 0 or 3 position The Kip Handles tighten the settings in place Backset 0 and 3 Degree 0 and 3 Degree Kip Handle FIGURE 2 5 Location of ...

Page 31: ...ments Setting a 2 3 4 or a 2 3 8 Backset 1 Pull cone cylinder towards you 2 Rotate turret to desired backset and release cone cylinder The longer bolt on turret is the 2 3 4 and the shorter bolt is the 2 3 8 backset 2 3 4 2 3 8 Rotate Turret Pull Cone Toward you and Release Cone after setting the Backset FIGURE 2 7 Backset Adjustment ...

Page 32: ...3 Lift the router and turn the bottom turret to the correct color 4 Turn the air back on Turret Router Turret FIGURE 2 8 Face Plate Adjustment Note If both the plate and latch hole are off center contact KVAL for instructions on shimming the self centering clamp system Setting the Router Depth Adjust the router depth for a 0 or 3 bevel door Set the router depth to the appropriate settings See Figu...

Page 33: ...Loosen Adjustment Bolts to move router Rotate Turret 3 Degree 0 Degree Setup of the EP 1 2 11 KVAL EP 1 Operation Service Manual FIGURE 2 9 Router Adjust ...

Page 34: ...1 Ensure factory air is applied to machine and main air supply is turned on 2 Make sure the electrical disconnect on the electri cal cabinet is turned to the ON position 3 Pull the CONTROL TRANS FORMER out to the On posi tion It should light up 4 Push the green START MACHINE button 5 All lights on the status light panel on the electrical box should be illuminated Note If a status light does not tu...

Page 35: ...ve Edge Prep switch on the control panel to Drill Both or Router Drill only drills the latch bore Router routes only the faceplate Both routes the faceplate then drills the latch hole Move a Door into Position and Start Sequence 1 Put a door on rollers and align lock hole to cone Align Lock Hole to Cone FIGURE 2 10 Move a Door into Position ...

Page 36: ...t pedal to secure door 4 Press the Start Sequence foot pedal to machine the door 5 After the process is complete the cutting tools will retract and the door clamps will release Move the door to the next process 6 To machine the next door repeat step 1 through step 5 Machining a Door 2 14 KVAL EP 1 Operation Service Manual ...

Page 37: ... panel to stop the machine 2 Push the CONTROL TRANS FORMER switch into the OFF position This kills power to the machine All status lights should be off 3 KVAL also recommends that you turn the disconnect switch on the electrical cabinet to OFF this helps reduce possible damage resulting from power surges from electrical storms ...

Page 38: ...How to Power Down the EP 1 2 16 KVAL EP 1 Operation Service Manual ...

Page 39: ...AL machine maintained is an important piece for successful operation of your door production process Chapter 3 at a Glance Maintenance Schedule 3 2 Daily 3 2 Weekly 3 2 Six Month Checkups 3 3 Lubrication Requirements 3 4 Linear Bearings Flange Bearing and Pillow Blocks 3 4 Gear Motor Lubrication Requirements 3 5 Description of Air Input System 3 5 Adjusting the Air Line Lubricator 3 5 Priming the ...

Page 40: ...oved 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 Daily Blow off dust from the entire machine Lubricate linear bearings and chrome shafts with silicone see lubrication require ments on Wipe down the outside of the machine with a clean dry cloth Check tooling for wear Check the air pressure to make sure it is set betwee...

Page 41: ...with soapy water Grease all bearings and tighten all bolts Access to some grease fittings is difficult and will require a special needle point grease tip supplied with your system Clean and lubricate all slides and cylinder rods with dry silicone spray Tighten all bolts Check mufflers or filters on exhaust ports on air valve banks They may need to be cleaned so the air can exhaust correctly ...

Page 42: ...systems on the machine Linear Bearings Flange Bearing and Pillow Blocks If the bearing is equipped with a grease fitting Zerk Fitting it should receive 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 every 250 hours of operation Note Bearings without grease fittings have been pre lubricated at the factory and do not require further lubrication Zerk Fittings Zerk Fitting Loca...

Page 43: ...cated air to valve banks and air cylinders Shop Air Input Air On Off Knob Muffler Filter w purge Pressure Gauge with adjust Clean Dry Air CDA to Air Blow Off Lubricator Lubricated Air Output FIGURE 3 2 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 s...

Page 44: ... lubricators is as fol lows KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32 Gulf 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 o...

Page 45: ...ts 4 3 Troubleshooting Electrical Problems 4 4 If the Power Stops During Normal Operation 4 4 Troubleshooting with the Status Light Panel 4 5 Troubleshooting the Air Cylinders 4 10 Adjusting Cylinder Extension Speed 4 11 Adjusting Cylinder Retraction Speed 4 11 Refer to the Air and Electrical drawings provided with delivery of the machine The drawings are normally located in the Electrical Panel I...

Page 46: ... to the position at which the switch actuates with a click is either 5 or 20 degrees The EP 1 has three 20 degree switches If the arm is moved to the full extent of its travel and you do not hear the limit switch click the switch needs to be adjusted Use the set screw on the limit switch arm and adjust the arm to activate at the desired degree of rotation see illustrations below The EP 1 has three...

Page 47: ...f all four parameters are out of calibration Check and adjust the bolts that raise and lower the assembly If one parameter is out of specification adjust that bolt linked to that parameter See Figure below Run all four parameters on a door If all four parameters are out of specification Check and adjust these two bolts Repeat until in specification If only one parameter is out of specification adj...

Page 48: ...chines 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 a...

Page 49: ...pective 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 50: ... the CONTROL POWER light STEP 1 Control Power Amber If light is OFF go to item A on page 4 7 STEP 2 Overload Relay Amber If light is OFF go to item B on page 4 7 STEP 3 E Stop Amber If light is OFF go to item C on page 4 8 STEP 4 Stop Amber If light is OFF go to item D on page 4 8 STEP 5 Start Amber If light is OFF go to item E on page 4 8 STEP 6 24VDC Green light is OFF go to item F on page 4 9 T...

Page 51: ...ower on the output side and there is power going into the top of the Control Transformer replace the Control Transformer 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 Control Power Light OFF 1 Check Motor Overload Circuits 2 With power on check the trip indicator LED on the overload If indi...

Page 52: ...art button If no voltage check the Stop button to make sure it is all the way out and not stuck in then check the contact to make sure it is closed If still no voltage check the wiring Start Light OFF Push the Start button If the Start light remains unlit push in the Start button and hold it in while a second person checks for voltage between 2 and 5 If there is 110 VAC replace the ACR relay If th...

Page 53: ...rown Red and Blue Black wires to the 24VDC power supply Trace the Brown Red wire to the DC terminal block Disconnect all brown wires from the DC from the DC terminal block except the Brown Red wire form the 24VDC power supply Check for 24VDC at between any DC and DC terminal on the DC Terminal block Reinstall the brown wires one by one checking for 24VDC after installing each brown wire If at any ...

Page 54: ...er and the opposite is true for the retract motion 1 Check the air pressure to the machine 2 Check the flow controls to see that they are adjusted correctly and to the proper specifications 3 Check for any obstructions to the cylinders such as screws or a misplaced tool etc FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS Manual over ride button 4 Check the solenoid air valves Once activ...

Page 55: ...valve It maybe is necessary to purchase a rebuild kit or a new cylinder c If the valve is not receiving an electrical signal for instructions It might be necessary to call in a specialist or check with KVAL Customer Service at 1 800 553 5825 5 If an Air Leak is coming from an exhaust port on the solenoid air bank a Check the solenoid for the manual override If the solenoid has a manual over ride y...

Page 56: ...Troubleshooting the Air Cylinders 4 12 KVAL EP 1 Operation Service Manual ...

Page 57: ...4 2 example 4 2 location on EP 1 4 2 router 4 2 linear bearing maintenance schedule 3 2 lock out procedure 1 7 Lockout and Tagout Guidelines 1 8 M main electrical panel description 2 5 maintenance daily 3 2 six month 3 2 weekly 3 2 manual part number 1 2 O overload relay light description 2 6 P part number manual 1 2 pillow block bearing maintenance schedule 3 2 PLC location 2 5 power disconnect s...

Page 58: ...2 KVAL EP 1 Operation Service Manual T thermal overload relay location 2 5 troubleshooting using status lights 4 4 V VFD location 2 5 Z zerk fittings 3 4 zero energy start up clean up1 10 inspect 1 10 ...

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