Kval 994-X User manual

Brand: Kval

Model: 994-X

Type: User manual

Innovation, Quality & Honesty

Includes Option RTS

994-X Pre-Hanging Door System

Service Manual

Published: 12/26/2021

KVAL 994-X Service Manual

Proprietary Notice

This Manual is confidential and contains proprietary information and intellectual

property of KVAL Inc., and is to be used solely by Customer as an operating manual for

KVAL Inc. machines. Neither this Manual nor any of the information contained herein

may be reproduced or disclosed under any circumstances without the express written

permission of KVAL Inc. For authorization to copy this information, please call Kval

Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and

Canada, call (707) 762-7367.

Manual Part Number: DOC-204-3-SRV (Start at SN 028)

The 994-X Door Hanging System is a trademark of Kval Incorporated.

Beckhoff® , TwinCAT ® , and EtherCat® are registered trademarks and are licensed

by Beckhoff Automation GmbH

Windows ® is a registered trademark of Microsoft Corporation.

All other products are trademarks or registered trademarks of their respective holders,

or sponsorship of Kval Incorporated.

Contacting KVAL

Customer Service: For further information about this manual or other Kval Incorpo-

rated products, contact the Customer Support Department

• Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

• Phone and Fax:

In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Business hours:

Technical Support:

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

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

Parts & Service Sales:

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

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

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

• Email: [email protected]

KVAL 994-X Service Manual

Your Feedback is Welcome: To help us design products that make your job easier

and your business more successful, we'd like to gain your perspective about your 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 [email protected]. (NOTE: This is not a customer support email

link. For that, please refer to the Customer Service contact information above.) Thank

you!

http://www.kvalinc.com

KVAL 994-X Service Manual

Table of Contents

Kval 994-X Service Manual

Chapter 1 Introduction to the 994-X System

Overview of the 994-X Door Hanging System ......................... 1-2

Available Options..................................................................................1-3

About this Manual.................................................................................1-6

Safety First!.............................................................................. 1-7

Safety Sheet Sign-Off Sheet.................................................................1-7

Safety Terminology of Labels................................................................1-7

Safety Guidelines..................................................................................1-7

Lockout-Tagout Guidelines ...................................................... 1-11

Follow the P-R-O-P-E-R lockout rule of thumb...................................1-11

Lockout Tagout Procedure....................................................... 1-12

Pre-Steps Before Lockout Tagout.......................................................1-12

Lockout Tagout Power ........................................................................1-12

Lockout Tagout Air Supply ..................................................................1-13

Start Maintenance...............................................................................1-13

Post Maintenance Steps.....................................................................1-13

Zero-Energy to Start-Up .......................................................... 1-14

Getting Help from KVAL........................................................... 1-16

Kval Return and Warranty Policy ............................................. 1-17

Send the Item .....................................................................................1-17

Acceptance of Return .........................................................................1-17

Refund Turnaround Time....................................................................1-17

Kval Errors..........................................................................................1-17

Customer Errors .................................................................................1-18

Shipper Errors.....................................................................................1-18

Warranty Replacement Parts..............................................................1-18

How to Download the Service Application ............................... 1-19

Download Application .........................................................................1-19

Safety Sign-Off Sheet .............................................................. 1-22

A Note to the Operator........................................................................1-22

Chapter 2 System IT Administration

System IT Administration ......................................................... 2-2

About the 994-X Computer...................................................................2-2

Connections on the PLC.......................................................................2-2

Backing up the Computer .....................................................................2-3

About Remote Connection to KVAL Service.........................................2-3

Kval 994-X Service Manual

Table of Contents

Chapter 3 Maintenance of the 994-X

Maintenance Schedule ............................................................ 3-2

300 Cycle Maintenance Steps ................................................. 3-4

Clean, Clean, Clean!.............................................................................3-4

600 Cycle Maintenance Steps ................................................. 3-5

Check Air Gauges and Inspect Water Traps.........................................3-5

Inspect Tooling......................................................................................3-5

Lubricate inside of Hopper....................................................................3-6

Empty Dust Collection Units .................................................................3-6

3,000 Cycle Maintenance Steps .............................................. 3-7

Inspect Feed Belts................................................................................3-7

Inspect Screw Drop Tubes on Six Shooter ...........................................3-7

Inspect all Photo Eyes ..........................................................................3-7

Inspect Limit Switches ..........................................................................3-8

Inspect Screw Receiver Parts...............................................................3-8

Inspect Airlines......................................................................................3-9

Refill Lubricators...................................................................................3-9

Grease Ball Screw Bearings...............................................................3-10

Clean Bearing Shafts..........................................................................3-10

12,000 Cycle Maintenance Steps............................................ 3-11

Inspect Chains for Proper Tension......................................................3-11

Inspect Air Cylinders ...........................................................................3-11

Inspect Hydraulic Lines.......................................................................3-11

Inspect Ball Rail Shafts.......................................................................3-12

Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........3-12

Clean inside Hopper ...........................................................................3-12

72,000 Cycle Maintenance Steps............................................ 3-13

Inspect Nuts and Bolts........................................................................3-13

Check Door Feeding Transition ..........................................................3-13

Electrical .............................................................................................3-13

Computer Backup...............................................................................3-13

Wash Filter and Lubricator Bowls .......................................................3-14

Tool Changing Schedule.......................................................... 3-15

Maintenance NO-GOES .......................................................... 3-16

Lubrication Schedule ............................................................... 3-17

Typical Lucubration Kit........................................................................3-17

Lubrication Requirements........................................................ 3-18

Pillow Block Bearing Housings ...........................................................3-18

Flange Bearing Housings ...................................................................3-19

Table of Contents

Kval 994-X Service Manual

Ball Rail Bearing .................................................................................3-19

About Taper Bearings .........................................................................3-20

Tapered Bearing Housings .................................................................3-20

Ball Screw Nut ....................................................................................3-21

Ball Screw Drive Assembly .................................................................3-21

Pulley and Idler Shafts........................................................................3-22

Sample of Grease Locations for 994-X.................................... 3-23

Back Section Servo Motor Assembly..................................................3-23

Front Section Servo Assemblies.........................................................3-24

Cutting Head Base..............................................................................3-25

Cutting Head Tools .............................................................................3-26

Grease Location on the Frame...........................................................3-27

Description of Air Input System................................................ 3-28

Air Input with Lubrication ...................................................................3-28

Air Line Without Lubricator .................................................................3-29

Replacing Tooling in the Front Section .................................... 3-30

Replacing Bits in the Front Section.....................................................3-30

Identifying Cutting Tools........................................................... 3-31

Tool Information for the Cutter Head...................................................3-31

Tool Information for the Back Section .................................................3-32

How to Access to Bit Assemblies........................................................3-33

Remove and Replace the Router or Pre-Drill Bits ..............................3-33

Remove and Replace the Chisels ......................................................3-35

Remove and Replace the Screwdriver Bits ........................................3-36

Replacing Tooling in the Back Section..................................... 3-39

Option SB (CNC Back Section) ..........................................................3-39

Changing the Bore Drill.......................................................................3-39

Changing the Bolt Drill........................................................................3-40

Collet Torque Values................................................................ 3-41

Chapter 4 Troubleshooting the 994-X

About Motion Control ............................................................... 4-2

Get Live Technical Help ........................................................................4-2

Basic Control Circuit .............................................................................4-2

Typical Positioning Systems .................................................................4-4

Troubleshooting Basics ........................................................... 4-7

Before you Adjust..................................................................................4-7

Analyze the Sub Systems.....................................................................4-8

About a Typical Contactor Control ........................................... 4-10

Kval 994-X Service Manual

Table of Contents

About Contactor Troubleshooting .......................................................4-11

About Typical VFD Motor Drive Control................................... 4-12

About the VFD ....................................................................................4-13

About VFD Troubleshooting................................................................4-14

About a Typical Pneumatic Circuit ........................................... 4-15

Typical Pneumatic Assembly ..............................................................4-16

About the Coil (Solenoid)....................................................................4-16

About Cylinder Operation ...................................................................4-17

How the Pneumatic System Works ....................................................4-17

Important Notice about Adjusting Cylinder Speed ..............................4-19

Adjusting Cylinder Extend Speed .......................................................4-20

Adjusting Cylinder Retraction Speed .................................................4-20

Valve Bank Locations .............................................................. 4-21

Location of Valve Banks .....................................................................4-21

Using Sensors to Trouble Shoot .............................................. 4-22

Location of Sensors on 994-X ................................................. 4-23

Z Axis and Y Axis Front Section Sensors ...........................................4-24

X Axis Sensors Front Section .............................................................4-25

Troubleshooting Electrical Problems ....................................... 4-26

If the Power Stops During Normal Operation .....................................4-26

Troubleshooting with the Status Light Panel .....................................4-27

Network System Overview....................................................... 4-32

Connections to Servo Drives ..............................................................4-33

Connections to VFD’s (High Freq Panel)............................................4-34

Symptoms and Possible Causes ............................................. 4-35

1-1

CHAPTER 1 Introduction to the 994-X System

This chapter provides an overview of the KVAL 994-X Door Hanging System and important safety

information to follow when operating the machine.

Chapter 1 at a Glance

Section Name Summary Page

Overview of the 994-X

System

This section provides an overview of the 994-X.

This section includes a general description and a

table of available options

page 1-2

Safety! IMPORTANT safety information is described in

this section

page 1-7

Zero-Energy to Start-Up Procedure to power up your machine for the first

time.

page 1-14

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 center

hours, and return procedures

page 1-16

Safety Sign-Off Sheet A record to track operators that are trained on the

machine.

page 1-22

Overview of the 994-X Door Hanging System

KVAL 994-X Service Manual

1-2

Overview of the 994-X Door Hanging System

KVAL's 994-X offers a high-speed pre-hanging line with the additional flexibility of servo con-

trolled hinge routing sections. This includes high frequency spindles and programmable point to

point pre-drilling.

The 994-X is designed for both interior, exterior doors and jambs. It will accommodate 1-3/8" and

1-3/4" thick doors with a minimum width of 18" and a maximum width of 42”. Door lengths of 6'

8" or 8' 0" can both be machined. Hinge locations automatically shift between two pre-determined

factory set locations to accommodate both three hinge pockets (6’-8”) and four hinge pockets (8’).

Changeover does however require manual repositioning of the jamb clamp fixtures but can easily

be accomplished in under two minutes without the use of tools.

The door is power-fed into the machine and clamped into position. After the hinges are attached,

and machining is finished, the door and jamb automatically is off-feed as the next door enters the

machine

Hinge routing sections are completely servo controlled for pocket height, width, and depth. Each

hinge routing section is equipped with two 1-1/2 HP High Frequency spindle motors, one for rout-

ing and one for pre drilling on both the door and jamb. Servo motors allow the hinge router to

accelerate out of and decelerate into hinge corners eliminating over travel. Changeover from 3-1/

2” to 4” hinges is accomplished by selecting the desired size on the touch-screen.Our Point to

Point Pre-Drill system can be programmed to drill all common hinge patterns automatically.

Additionally, the use of servo motors allows you to machine both 1/4” and 5/8” radius corners

without changing out tooling.

Hinges may be attached manually or with the optional Six-Shooter to install 3-1/2" X 3-1/2"

hinges, or the optional Eight-Shooter for attaching 4" X 4" hinges while the door and jamb remain

clamped in position. Door-to-door productivity, including hinge mounting, is typically 35-55 sec-

onds. However, this varies depending on the operator and material flow.

The lock machining assembly will be positioned with a single servo driven ball screw. This is

controlled by the touch screen, and will allow settings for standard lock and dead bolt locations

based on the lock bore location. A third dead bolt bore may easily be added by entering the posi-

tion on the touch screen. The servo driven system will automatically position the lock boring

assembly when the door hand is changed. Lock detailing includes 2-1/8” face boring with push

button change over between 2-3/8” and 2-3/4” back sets; 1” bolt drill and face plate routing. Face

plate routing will be accomplished with a 1-1/2 hp Hi-Frequency spindle motor.

The 994-X will accommodate doors with raised molding one or both sides up to 3/4" high, and a

minimum of 4" between the raised molding and the edge of the door.

This machine is equipped with a solid state touch screen that replaces many of the mechanical

switches for the machine functions. The touch screen also includes the capability to view the sta-

tus of the various photo eyes and switches for quick diagnosis when needed, without having to

open the electrical panel or for the operator to leave his work station. The Touch Screen logic also

includes management functions such as Daily and Lifetime Totals.

Overview of the 994-X Door Hanging System

1-3

KVAL 994-X Service Manual

About the Six Shooter

The Six-Shooter screw gun will attach 3-1/2" X 3-1/2" hinges to the door and jamb, # 9 X 3/4"

long flat head screws are automatically sorted and fed, six at a time, to the screw gun. The opera-

tor manually places the hinge onto the magnetic indexing fixture and then rolls and pivots the Six

Shooter into an "H" block at each hinge location to attach the hinges. Pressing the 'Reset' switch

then raises the Six Shooter and feeds a set of six screws for the attachment of the next hinge.

The Six Shooter, which is supported on ball bearing equipped steel wheels and is mounted on an

overhead track. The track and the Six Shooter are precisely aligned to ensure the hinge is properly

position into the pocket at each hinge location.

Available Options

For detailed information about available options, please contact our KVAL Sales and Service

department.

Option Title Description

Option A Six Shooter Gun for 3-1/2'' X

3-1/2''

To attach 3-1/2" X 3-1/2" hinges to the door and jamb,

No. 9 by 3/4" long flat head screws are automatically

sorted and fed, six at a time, to the screw gun. Operator

manually places the hinge onto the magnetic indexing fix-

ture and then rolls and pivots the Six Shooter into an "H"

block at each hinge location to attach the hinges. Press-

ing the 'Reset' switch then raises the Six Shooter and

feeds a set of six screws for the attachment of the next

hinge.

NOTE: Requires Option D: Pre-Drill System for Six

Shooter.

The Six Shooter, which is supported on ball bearing

equipped steel wheels, is mounted on an overhead track

that is precisely aligned to ensure the hinge is properly

position into the pocket at each hinge location.

Option

AC:

Metal Door Sensing Proximity

Switch

Allows operator to do the edge prep on a steel door with-

out accidentally doing a face bore into the door.

RT-FX Single Head machine with

the Rotary Hopper stand. The

Rotary option allows kind change of

screw type with preloaded screws.

Overview of the 994-X Door Hanging System

KVAL 994-X Service Manual

1-4

Option

Ball Catch Drills Drill assemblies are mounted onto the lock boring section

for drilling left hand and right hand doors for drive-in ball

catches. When selected the proper drill automatically piv-

ots in to drill into the top of the door. Note, minimum door

width for drilling is 18".

Option

Corner Square Chisels Corner Square Option adds automatic corner squaring to

the hinge routing sequence in both the door and jamb.

Option includes two chisel mounting blocks per head,

each one containing two chisels. As one chisel is operat-

ing, the inactive chisel is in the reveal between the door

and jamb. For instance, when you are squaring the upper

right corner in the jamb, the lower right chisel will be in

the reveal. When the lower right chisel is squaring the

lower right corner in the door, the upper right chisels in

the reveal. Although two chisels are paired together in

one mounting block, each one is independently cali-

brated for vertical and horizontal travel as well as depth.

Option

Counter Rotating Routers The standard 994X relies on automatic chip-out blocks

clamped between door and jamb to protect the door face

and jamb edges from chipping during hinge routing. This

option eliminates the chip-out blocks by adding four extra

routers to the hinge detailing section with left hand rota-

tion. As hinge pockets are routed, the left hand rotating

routing tool is used to minimize chipping of the door face

or jamb edge.

Option E Two-Stage Drilling Allows changeover for two different face bore sizes with a

selection on the control panel.

Customer to specify 1-1/2” or 1-5/8” for dead bolt face

bore when ordering. Standard lock boring bit is 2/1/8".

Option IL Door Hand Indicator Light Light will be mounted on the out-feed end of the 990-F4

that can be seen by the 700-C Assembly Table operator.

The light will be on when the door in the 994-X is being

machined as a right hand door and off for a left hand

door.

Option K Eight-Shooter Screw Gun for

4" X 4" Hinge

To attach 4" X 4" hinges to the door and jamb, No. 10 by

3/4" long flat head screws are automatically sorted and

fed, eight (8) at a time, to the screw gun. Operator manu-

ally places the hinge onto the magnetic indexing fixture

and then rolls and pivots the Eight Shooter into an "H"

block at each hinge location to attach the hinges. Press-

ing the 'Reset' switch then raises the Eight Shooter and

feeds a set of eight (8) screws for the attachment of the

next hinge.

Option O Door Blow-Off System Air blow-off tube cleans dust and chips from top of door

as it feeds out of the 994-X.

Option N Weatherstrip Retaining

Brackets

Isolates Weather Strips during the routing process. A protective bar

across top of H block keeps the strip up and away from the routers.

Option Title Description

Overview of the 994-X Door Hanging System

1-5

KVAL 994-X Service Manual

Option

Servo Backsection with Cor-

ner Squaring

The 994-X system combines very high quality hardware

detailing, with high speed productivity. Unique features

include computer controlled ball screw movements for all

router and chisels, complete with square lock face plates.

Backsection will have the ability to machine a face plate

at both "0" and "3" degree. Operator can select widths

from 1" to 1-1/4" wide and up to 2-3/4" in length.

Option

Zero & Three Degree Hinge

Routing

Price includes PLC logic and controls to allow front hinge

routing section to rout on either a 0 degree or 3 degree

angle.

Hinges will be flush mounted when installed on doors

with either square edge or 3 degree bevel on hinge side

Option

Top Hinge Dimension Differ-

ent for 6'-8" and 8'-0" Door

In-feed door and jamb stops will be movable. Door stop

will be cylinder actuated.

NOTE: Specifications for hinge locations must be pro-

vided in order to prepare quotation.

Option

Hinge Stops for 6'8", 7'0" &

8'0" Doors

This option is limited to certain hinge pocket locations.

Hinge location specifications need to be submitted in

order to determine if they can be accommodated with the

994-X.

Option Z Screw-Changing Hopper for

Six Shooter

Screw-changing hopper for changing screw colors.

Option

Quick-Change Hopper for

Eight Shooter

Screw changing hopper for 8-Shooter allows for rapid

change of screw colors.

Quick Change Knuckle Hinge Switch located on the 8-shooter hinge applicator which

provides the ability to switch from a standard (narrow bar-

rel) knuckle hinge to a wide spring-knuckle hinge.

Changeover time between knuckle sizes is 1 second.

Narrow Door Support Supports doors between 12" - 16”

Structure utilizes air cylinders and 7 pairs of industrial

wheels for support - mechanism is automatically put in

and out of position via a selection

Split Jamb Staplers Two 1/4" crown staple guns are mounted onto the jamb

clamp brackets. While clamped in the machine, staples

will be driven into the back side of the split jamb to keep

the male and female together.

The staple guns are fired with a single valve that is inter-

locked with a safety switch to disable the staple guns

unless there is a jamb clamped in the machine.

Two staple guns with remote fires are required and are

not included in the price of the option.

Option Title Description

Overview of the 994-X Door Hanging System

KVAL 994-X Service Manual

1-6

About this Manual

This manual is part of a package delivered with the machine line.

Integration Package includes the following:

Operation Manual includes the following:

Service Manual includes the following

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

Operation Inter-

face

Descriptions of how to power

machine line, and operator inter-

face user screens.

3Calibration Descriptions of Calibration Rou-

tines and how to use the interfaces

Chapter Title Description

1Introduction Safety Information.

2System IT Admin-

istration

Descriptions of the PLC system,

and computer system.

3Maintenance Maintenance steps for the

machine line

4Trouble Shooting Troubleshooting tips and theory of

operation.

Safety First!

1-7

KVAL 994-X Service Manual

Safety First!

Safety Sheet Sign-Off Sheet

At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-

teria to understand before operating the machine. It is highly recommended that personnel operat-

ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be

signed and kept for records. See “Safety Sign-Off Sheet” on page 1-22.

Safety Terminology of Labels

In addition to the nameplate, KVAL machines may have other warning labels or decals that provide

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 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 guidelines below

to help ensure the safety of equipment and personnel.

This machine is a powerful electro-mechanical motion control

system. You should test your motion system for safety under

all potential conditions. Failure to do so can result in dam-

age to equipment and/or serious injury to personnel.

Ensure that all employees who operate this machine

are aware of and adhere to all safety precautions

posted on the machine and are trained to operate this

machine in a safe manner.

Training

Safety First!

KVAL 994-X Service Manual

1-8

Never operate the machine without proper eye and

ear protection.

Protective Gear

• Never reach hands beyond safety cage. Servo

motors can unexpectedly move quickly.

• Never clear screws or hinges out of the machine

while it is running.

• Never reach into the router area to retrieve a

hinge. The router may still be running down

after shut down.

• Never perform any maintenance unless machine

is at zero state.

• Never clean the machine while it is running.

• Never walk away from the machine while it is

running.

When the Machine is ON

The compressed air system connected to this

machine should have a three-way air valve

for shut-off and pressure relief.

All cylinders on machine are under high

pressure and can be very dangerous when

activated. Before performing any mainte-

nance or repairs on this machine turn off the

main air disconnect. Lockout and tagout

this connection.

See “Lockout Tagout Procedure” on

page 1-12.

Compressed Air

Safety First!

1-9

KVAL 994-X Service Manual

Electrical circuitry on this

machine is protected by an

approved lockable disconnect

circuit. In addition to this equip-

ment, you must install an

approved disconnect for the

electrical power supplying this

machine.

When opening the cabinet you must first turn off the

disconnect switch. When the cabinet door is open there

is still power on the top side of the disconnect switch.

Some machines are powered by more than one supply

located at different locations. Before performing any repairs or mainte-

nance, lockout and tagout must be installed at all locations

All maintenance and repairs to electrical circuitry should only be per-

formed by a qualified electrician.

Still has power

in OFF position

Electrical

Prior to performing any maintenance, repairs,

cleaning or when clearing jammed debris, you

must disconnect, tag out, or lock out the electrical

and air pressure systems. This should be done in

accordance with applicable state and/or federal

code requirements.

Before Conducting Maintenance

Laser Warnings

On some machines, laser indicators are used to set boundaries. Follow the

manufacturers safety precautions.

Safety First!

KVAL 994-X Service Manual

1-10

KVAL advises that you request an on-site state

safety review of your installation of this

machine. This is to ensure conformance to any

additional specific safety and health regula-

tions which apply in your geographic area.

Compliance with Codes and Regulations

Other Hazard Control Action

Report a Hazard

Before You Report an Accident

If you believe any part or operation of this machine is in

violation of any health or safety regulation, STOP pro-

duction. It is your responsibility to immediately protect

your employees against any such hazard.

Additional detailed safety guidelines are included in the

operating instructions of this manual. KVAL will be

pleased to review with you any questions you may have

regarding the safe operation of this machine

Follow Your Company’s Safety Procedures

In addition to these safety guidelines. Your company

should have on-site and machine specific safety proce-

dures to follow.

Lockout-Tagout Guidelines

1-11

KVAL 994-X Service Manual

Lockout-Tagout Guidelines

• Place a tag on all padlocks. On the tag, each

operator must put their own name and date.

(These locks are only to be removed by the

person who signs the tag)

• If more than one person is working on the

machine, each additional person places a lock

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 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

Lockout Tagout Procedure

KVAL 994-X Service Manual

1-12

Lockout Tagout Procedure

This policy is required by OSHA regulation 1910.147 and Cal OSHA’S

SB198 ruling of July 1991.

Use the following lockout procedure to secure this machine while it is

powered down. During a lockout, you disconnect all power and shut

off the air supply. Be sure to use the tagout guidelines noted below.

Pre-Steps Before Lockout Tagout

Lockout Tagout Power

1. Evaluate the equipment to fully understand all energy sources (multiple electrical

supplies, air supply and pressure, spring tension, weight shifts, etc.).

2. Inform all affected personnel of the eminent shutdown, and the duration of the

shutdown.

3. Obtain locks, keys, and tags from your employer’s lockout center.

4. Turn off machine. See Chapter 2 for power down and power up procedures.

5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF

position. Then push the red tab to pop it out. Place a padlock through the hole.

Place your tag on the padlock, as per the tagout guidelines below. (see illustration

below).

Power

Note: When multiple people are working on the machine, each person needs to

have a lock on the handle in the extra holes provided.

Insert Lock into hole.

Turn Switch to the

OFF position

Lock and Tag out

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