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Troubleshooting Basics

3-4

KVAL Manual

Troubleshooting Basics

Good trouble shooting starts with looking at the whole machine, where every part is suspect. Then

narrowing down the view to the bad part.

Ask:

Ask basic questions. For example:

• What was the Machine Trying to Do?
• What Was the Machine Trying to Do Next?
• Was the machine working before?
• Did it happen on first power up or during process?

Narrow:

Narrow or determine the sequence and subsystem where the issue occurs. For example:

• Did the issue happen when door was being fed in?
• 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?

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Summary of Contents for ON-3

Page 1: ...Innovation Quality Honesty Service Manual Published February 02 2021 ON 3V Door Lift System ON 3V Service Manual ...

Page 2: ...stered 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 Depa...

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

Page 4: ...KVAL ON 3V Service Manual ...

Page 5: ... 1 9 Lockout Tagout Air Supply 1 10 Start Maintenance 1 10 Post Maintenance Steps 1 10 Zero Energy to Start Up 1 11 Getting Help from KVAL 1 13 Safety Sign Off Sheet 1 16 A Note to the Operator 1 16 Chapter 2 Maintenance of ON 3V Maintenance Schedule 2 2 Daily Monthly Six Month Maintenance 2 2 Lubrication Requirements 2 4 Typical Lucubration Kit 2 4 Bearing Descriptions 2 5 Pillow Block Bearing Ho...

Page 6: ...al Contactor Control 3 5 About Contactor Troubleshooting 3 6 About Typical VFD Motor Drive Control 3 7 About the VFD 3 8 About VFD Troubleshooting 3 9 About a Typical Pneumatic Circuit 3 10 Typical Pneumatic Assembly 3 11 About the Coil Solenoid 3 11 About Cylinder Operation 3 12 How the Pneumatic System Works 3 12 Important Notice about Adjusting Cylinder Speed 3 14 Adjusting Cylinder Extend Spee...

Page 7: ... available options page 1 2 Safety First 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 11 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 the specifi cation plate tor provide to KVAL service c...

Page 8: ...The table below lists the available Options for this machine Check the machine contract to verify what options are applied to your machine TABLE 1 1 Options Available Option Title Description Option L Raised Moulded Doors This option adds the capacity to feed doors with raised moulding on either or both sides Maximum moulding height above door face will be 3 4 inch Spacers used to stack doors must...

Page 9: ... Line and Safety Information 2 Operation Interface Descriptions of how to power machine line and operator inter face user screens 3 Tour of ON 3V Identification and descriptions of the ON 3V machine assemblies Chapter Title Description 1 Introduction Safety Information 2 System IT Admin istration Descriptions of the PLC system and computer system 3 Maintenance Maintenance steps for the machine lin...

Page 10: ...legible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if the warning is not heeded it can cause death or serious injury CAUTION means if the precaution is not taken it may cause minor or moderate injury Safety Guidelines In addition to the caution and warning labels affixed to this machine follow the ...

Page 11: ...perform any maintenance unless machine is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before performi...

Page 12: ...fferent locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out the electr...

Page 13: ...believe any part or operation of this machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed safety guidelines are included in the operating instructions of this manual KVAL will be pleased to review with you any questions you may have regarding the safe operation of thi...

Page 14: ...n each disconnect Only each operator may remove their own lock and tag Important When many people are all working on the same machine you will need a multiple lockout device such as the one shown here Follow the P R O P E R lockout rule of thumb P Process shutdown R Recognize energy type electrical pneumatic mechanical etc O OFF Shut off all power sources and isolating devices P Place lock and tag...

Page 15: ...nd pressure spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shutdown 3 Obtain locks keys and tags from your employer s lockout center 4 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to pop it out Pla...

Page 16: ...etely removed and that all guards and safety devices are installed 10 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 11 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 12 The tags must be destroyed and the lock...

Page 17: ...ergy 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 comprehensive...

Page 18: ...our 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 19: ...t number 2 Contact our customer support team In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email address is service kvalinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday What is the extent of the failure reason for return What are the relevant ...

Page 20: ...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 returning are securely packaged and well protected from shipping damage ...

Page 21: ...Getting Help from KVAL 1 15 KVAL Manual Page Intentionally Left Blank ...

Page 22: ...mpany s safety procedures I have read and understand these guidelines Machine Safety Concerns I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the electrical power ...

Page 23: ...es to sched ule for maintenance Daily Weekly 5 Six Month Checkups page 2 2 Lubrication Requirements This section describes the lubrication require ments for the machine including types of lube to use This section includes Linear Bearings Flange Bearing and Pillow Blocks Gear Motor Lubrication Requirements Ball Screws Description of Air Input System Adjusting the Air Line Lubricator Priming the Air...

Page 24: ... Daily Preventive Maintenance Op Operation Description Clean Blow off dust from the entire machine Wipe down the outside of the machine with a clean dry cloth Check Check tooling for wear Clean Wipe off the photo eyes with a clean dry cloth and check to ensure that all fas tening nuts are snug Check Check the air pressure to make sure it is set at 80 psi to100 psi Clean Empty any Dust Collection U...

Page 25: ...with an ISO 32 standard hydraulic oil KVAL part SYSLUBG Six Month Preventive Maintenance Op Operation Description Clean Wash filter and lubricator bowls with soapy water LUBE Grease all bearings and tighten all bolts Access to some grease fittings is diffi cult and will require a special needle point grease tip supplied with your sys tem Clean Clean and lubricate all slides and cylinder rods with ...

Page 26: ...Hours of Machine Operation Dura Lith Grease KVAL P N Lube EP 2 Pillow Block Bearing Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Idler Shafts Pulley Monthly Tapered Bearing One Pump 4 X a Year Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Note Some CNC Machines drop every 5 10 cycles Either lubricant listed below is approved ...

Page 27: ... is basically a valve that opens under pressure to allow lubricant to pass through a channel and be forced into the voids of the bearing When the pressure stops the ball returns to its closed position The ball excludes dirt and functions as a check valve to prevent grease escaping back out of the fitting The ball is almost flush with the surface of the fitting so that it can be wiped clean to redu...

Page 28: ...ration FIGURE 2 2 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 2 3 Ball Rail Bearings Greasing Flange Bear ing Bearing Housings Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 250 hours o...

Page 29: ...er 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 getting excess grease on the belts Idler Shaft Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Monthly ...

Page 30: ...r tank at all times so that if the machine is turned off overnight the lifting chain does not experience excess slack that may bind when air is returned to the machine FIGURE 2 4 Air Assist System Caution Due to this system design the air system should be depressurized prior to servicing the Air Assist Chain System or the Vertical Lift Assembly Shutdown the machine and follow the Lockout Tagout Pr...

Page 31: ...pace below the lift assembly is clear of any potential crushing or pinch ing Climb up to the air tank then turn the air exhaust valve to exhaust EXT to remove pressured air from the system 4 As the tank pressure falls the air assist cylinders should extend relax and a small amount of slack in the assist chain should form If there is still tension in the chain system inspect for any binding Remedy ...

Page 32: ... Pillow Block Bearing Housings on page 2 5 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 Lockout Tagout Procedures Caution Opened Pillow Block 4 outer Vertical 4 Inner Vertical 4 Horizontal Approxima...

Page 33: ...re maintenance For rec ommended greasing schedule see Maintenance Schedule on page 2 2 Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every 250 hours of operation Hub Bearings 2 Total Pulley Idler Shaft Bearings 4Total The Stacker Table adds pop up door stops located at the end of the table 4 Bearings Total ...

Page 34: ...he lubricated air to valve banks and air cylinders FIGURE 2 5 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 Knob Muffler Filter purge Pressure Gauge with adjust Clean Dry Air CDA to Air Blow Off Lubricator Lubri...

Page 35: ... To prime the lubricator find an air line on the carriage section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose Repeat this same procedure for the back section and other trouble areas It is recommended to check the lines...

Page 36: ...Description of Air Input System 2 14 KVAL Manual ...

Page 37: ...ng page 3 4 About Contactor Control Describes a typical contactor control circuit page 3 5 About VFD Control Describes a typical VFD circuit page 3 7 About Pneumatic Control Describes the typical pneumatic circuit page 3 10 Using Sensors to Trouble Shoot Includes procedure to trouble shoot air cylin ders such as adjusting extension and retrac tion speed page 3 16 Troubleshooting Electrical Problem...

Page 38: ...m 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 to multi...

Page 39: ...lates 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 dedicated mo...

Page 40: ...he Machine Trying to Do Next Was the machine working before Did it happen on first power up or during process Narrow Narrow or determine the sequence and subsystem where the issue occurs For example Did the issue happen when door was being fed in 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 H...

Page 41: ...ock Diagram of a Common Contactor Circuit High Voltage may cause personnel injury or death Troubleshooting checks must be performed by a Qualified Electrical Technician PLC Output Fuse s Line Voltage Power Contactor Control Coil Input Power Input Power Output Control Circuit Common ON Should measure Control Voltage 120 VAC here Should measure Line Voltage here Should measure Line Voltage here Line...

Page 42: ...uit See Description of the Light Tower on page 3 19 1 Open the Main Electrical Cabinet to find the Contactor Thermal Overload Assem bly 2 Press each Green Reset button on the Thermal Overload An audible click will be heard on the tripped circuit Take note of tripped circuit 3 Once the overloads are reset verify LED s are on 4 Rerun the machine and verify that motor runs without tripping the circui...

Page 43: ...ay 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 300 Run L...

Page 44: ...ee Figure 3 14 on page 3 7 FIGURE 3 15 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 purposes Fa...

Page 45: ...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 motor cir...

Page 46: ...Pneumatic Circuit PLC Output High Pressure Air Cylinder Common Control Circuit ON Measure 24 VDC here Control Voltage Should have High Pressure air here Cylinder Control Control Coil Input Air Input Air Output Valve Should have High Pressure air on Activated Output Schematic Drawing of Pneumatic Circuit Note Pre 2006 machines may not contain the 24 Volt relay 120 Vac is directly fed into the Contr...

Page 47: ...enoid body Use this information to troubleshoot system if nec essary FIGURE 3 19 Solenoids in Manifold Air Input Cylinder Retract Cylinder Extend Electrical Wiring Box Con tains inputs from PLC to Coils Solenoids Manifold Base to accept air input and output air Coil Solenoid Receives input 24V from PLC to open a port Solenoid type will vary with machine application Common controls include an opera...

Page 48: ...the process to move a router to the extend and the retract position with a double valve Extend Process If PLC determines the conditions are right to extend the Router 1 The PLC applies the control voltage to the Control Valve which directs com pressed air to extend port of the Cylinder 2 The Cylinder and Router are extended deactivating the Retract Sensor 3 The Router fully extends activating the ...

Page 49: ...and Router retract deactivating the Extend Sensor 3 When the Cylinder and Router are fully retracted the Retract Sensor is activated 4 The PLC senses the voltage from the Retract Sensor completing the process Positioning System Load Force Translated Positioning PLC Instructions Position Feedback Extend Sensor Retracted Sensor Deactivated Activated 24 Volts Extended Cylinder 24 V Applied Router Ass...

Page 50: ...lipping screws in Hoppers However sometimes machine settling mechanics be broken in may be cause to slightly adjust extend and retraction speed If more than 1 2 turn on adjustment knobs are needed call in a specialist or check with KVAL customer service at 1 800 553 5825 Cylinder 0 V Router Assembly Load Position Feed Back Air In Control Valve Retract Sen sor Acti vated Air Pressure Retracts Cyl i...

Page 51: ... 15 KVAL 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 52: ... 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 to the door should be in range Typically the range should be 3 4 to 7 8 from the top of all eyes to the door ...

Page 53: ...ng the lights turn on or off Compare the lights on the IDEC or Beckhoff controllers to the electrical print to determine what systems are being affected If the Power Stops During Normal Operation 1 Check that the input power disconnect switch is not turned off 2 Check that all of the emergency stop buttons are in the normal position 3 Check the Six Lights on the Electrical Panel See Description of...

Page 54: ...tops tripped 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 it can be electrically jumped to check operation 4 With the power off check for motor overloads by pressing each reset button usu ally at the bottom of the panel in SEQUENCE If one is...

Page 55: ... Machine Error Solid General Error 1 Flash EtherCat Device not Ready to Run 2 Flashes VFD Servo or Motor Error 3 Flashes 24 VDC Power Error Yellow External Error Solid General Error 1 Flash 3 Phase Voltage Error 2 Flashes Low Air Error Blue Operator Status Solid Waiting for Operator 1 Flash Reposition Door Green Machine is Operational Safety OFF Clear Safety Project not Running Red Safety PLC Erro...

Page 56: ...ot lubricating machine 1 Oil Reservoir Empty 2 Lubricator Not Primed 3 Faulty Lubricator 1 Fill Reservoir with Sys lube 2 Prime lubricator 3 Replace Lubricator Feed System Doesn t Stop for Door to Clamp 1 Debris on Photo Eye 2 Defective Photo Eye 3 Feed Belt Too Low 1 Clean Photo Eyes Regularly 2 Replace Eye 3 Adjust Feed Belt Height ...

Page 57: ...aring maintenance schedule 4 L linear bearing maintenance schedule 4 lockout and tagout Guidelines 11 lockout procedure 9 M maintenance daily 2 3 six month 2 weekly 2 P pillow block bearing maintenance schedule 4 power lock out procedure 9 power up troubleshooting 17 S safety guidelines 4 Safety Sign Off Sheet Safety Concerns 16 sensors troubleshooing 16 six light panel description 19 T tagout pro...

Page 58: ...Index Kval ON 3V ...

Page 59: ......

Page 60: ...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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