Kval 995-H Operation And Service Manual

Brand: Kval

Model: 995-H

Type: Operation And Service Manual

Innovation, Quality & Honesty

995-H Jamb Routing System

995-H Operation and Service Manual

Operation and Service Manual

Published: March 5, 2021

KVAL 995-H Operation and 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-220-2-OPS

995-H is a trademark of Kval Incorporated.

Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed

by Beckhoff Automation GmbH

Windows 7® is a registered trademark of Microsoft Corporation.

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

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 995-H Operation and Service Manual

Your Feedback is Welcome:          

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             

                

            -

   NOTE:       

            





KVAL 995-H Operation and Service Manual

Table of Contents

KVAL 995-H Routing and Hinge Application System

Chapter 1 Introduction to the 995-H

Chapter 1 at a Glance...........................................................................1-1

Overview of the........................................................................ 1-2

SPECIFICATIONS ................................................................................1-2

Options Available ..................................................................................1-2

About this Manual.................................................................................1-3

Safety First!.............................................................................. 1-4

Safety Sheet Sign-Off Sheet.................................................................1-4

Safety Terminology of Labels................................................................1-4

Safety Guidelines..................................................................................1-4

Lockout-Tagout Guidelines ...................................................... 1-8

Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-8

Lockout Tagout Procedure....................................................... 1-9

Steps Before Lockout Tagout................................................................1-9

Lockout Tagout Power ..........................................................................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

KVAL Return and Warranty Policy ........................................... 1-14

Send the Item .....................................................................................1-14

Acceptance of Return .........................................................................1-14

Refund Turnaround Time....................................................................1-14

Kval Errors..........................................................................................1-14

Customer Errors .................................................................................1-15

Shipper Errors.....................................................................................1-15

Warranty Replacement Parts..............................................................1-15

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 995-H

Operator’s Tour ........................................................................ 2-2

The 995-H Process Summary ..............................................................2-2

Machine Components...........................................................................2-2

Top View of Machine.............................................................................2-3

KVAL 995-H Operation/Service Manual

Table of Contents

Front Section ........................................................................... 2-4

Operator Station ...................................................................................2-5

About the Foot Pedal............................................................................2-5

About the Safety Curtain.......................................................................2-6

About the Three Shooter and Hinge Carriage ......................................2-7

Hinge Carriage......................................................................................2-8

Option Counter Rotate Router..............................................................2-8

Standard Tool Set .................................................................................2-9

Three Shooter System........................................................................2-10

About the Hopper................................................................................2-10

About the Jamb Screw Delivery..........................................................2-12

Driver Assembly..................................................................................2-14

About the Electrical Panels...................................................... 2-15

Description of the Six Light Panel ......................................................2-16

About Switches and Sensors................................................... 2-17

Quick Start ............................................................................... 2-19

Powering Operations for the 995-H ......................................... 2-21

How to Power Up the 995-H...............................................................2-21

Home the 995-H .................................................................................2-22

How to Power Down the 995-H ..........................................................2-22

Emergency Shutdown and Recovery .................................................2-23

To Resume Normal Operation after an E-Stop ...................................2-23

About The Automatic Safety Hook......................................................2-23

Screen Selection Menu Map.................................................... 2-24

Description of User Interface Screens ..................................... 2-26

Machine Feed Back...........................................................................2-26

Controlling Access to Setup Screens..................................................2-26

Main Screen............................................................................. 2-27

Main Screen Descriptions...................................................................2-27

Manual Operation .................................................................... 2-31

Manual Jog Screen.............................................................................2-31

About the Calibration ............................................................... 2-34

How to Enter Calibration Data ............................................................2-34

Enter a Positive or Negative Number? ...............................................2-35

Setup Hinges 1-3 Screens..................................................................2-36

About the Pre-Drill Screen..................................................................2-40

Entering Pre-Drill Pattern Data ...........................................................2-40

Diagnostic Screen.................................................................... 2-43

............................................................................................................2-44

Table of Contents

KVAL 995-H Routing and Hinge Application System

Chapter 3 System IT Administration

System IT Administration ......................................................... 3-2

About the 995-H Computer...................................................................3-2

Connections on the PLC.......................................................................3-2

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

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

Chapter 4 Maintenance of 995-H

Maintenance Schedule ............................................................ 4-2

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

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

600 Cycle Maintenance Steps ................................................. 4-5

Check Air Gauges and Inspect Water Traps.........................................4-5

Inspect Tooling......................................................................................4-5

Lubricate inside of Hopper....................................................................4-6

Empty Dust Collection Units .................................................................4-6

3,000 Cycle Maintenance Steps .............................................. 4-7

Inspect Screw Drop Tubes on Six Shooter...........................................4-7

Inspect all Photo Eyes ..........................................................................4-7

Inspect Limit Switches ..........................................................................4-7

Inspect Screw Receiver Parts...............................................................4-8

Inspect Airlines......................................................................................4-9

Refill Lubricators...................................................................................4-9

Grease Ball Screw Bearings...............................................................4-10

Clean Bearing Shafts..........................................................................4-10

12,000 Cycle Maintenance Steps............................................ 4-11

Inspect Air Cylinders...........................................................................4-11

Inspect Hydraulic Lines.......................................................................4-11

Inspect Ball Rail Shafts.......................................................................4-11

Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........4-11

Clean inside Hopper ...........................................................................4-12

72,000 Cycle Maintenance Steps............................................ 4-13

Inspect Nuts and Bolts........................................................................4-13

Electrical .............................................................................................4-13

Computer Backup...............................................................................4-13

Wash Filter and Lubricator Bowls .......................................................4-13

Tool Changing Schedule.......................................................... 4-14

Maintenance NO-GOES .......................................................... 4-16

KVAL 995-H Operation/Service Manual

Table of Contents

Lubrication Schedule ............................................................... 4-17

Typical Lucubration Kit........................................................................4-17

Lubrication Requirements........................................................ 4-18

Pillow Block Bearing Housings ...........................................................4-18

Flange Bearing Housings ...................................................................4-19

Ball Rail Bearing .................................................................................4-19

About Taper Bearings .........................................................................4-20

Tapered Bearing Housings .................................................................4-20

Ball Screw Nut ....................................................................................4-21

Ball Screw Drive Assembly .................................................................4-21

Grease Locations for the 995-H............................................... 4-22

Locations of Carriage Head Bearings.................................................4-22

Locations of Bearings on the Tool Box ...............................................4-23

Locations of Bearings for Each Tool ...................................................4-24

Standard Tool Set ...............................................................................4-25

Locations of Bearings on the Screw Driver Assembly ........................4-26

Description of Air Input System................................................ 4-28

Air Input with Lubrication ...................................................................4-28

Air Line Without Lubricator .................................................................4-29

Replacing Tooling in the Front Section .................................... 4-30

Tool Locations in the 995-H Carriage Head........................................4-30

How to Access to Bit Assemblies........................................................4-31

Remove and Replace the Router or Pre-Drill Bits (Point to Point) .....4-31

Remove and Replace the Screwdriver Bits ........................................4-33

Changing Chisels on a Machine .............................................. 4-36

Collet Torque Values................................................................ 4-37

Chapter 5 Troubleshooting the 995-H

About Motion Control ............................................................... 5-2

Basic Control Circuit .............................................................................5-2

Troubleshooting Basics ........................................................... 5-4

Before you Adjust..................................................................................5-4

Analyze the Sub Systems.....................................................................5-4

About a Typical Contactor Control ........................................... 5-6

About Contactor Troubleshooting .........................................................5-7

About Typical VFD Motor Drive Control................................... 5-8

About the VFD ......................................................................................5-9

About VFD Troubleshooting................................................................5-10

Table of Contents

KVAL 995-H Routing and Hinge Application System

About a Typical Pneumatic Circuit ........................................... 5-11

Typical Pneumatic Assembly ..............................................................5-12

About the Coil (Solenoid)....................................................................5-12

About Cylinder Operation ...................................................................5-13

How the Pneumatic System Works ....................................................5-13

Important Notice about Adjusting Cylinder Speed ..............................5-15

Adjusting Cylinder Extend Speed .......................................................5-16

Adjusting Cylinder Retraction Speed .................................................5-16

Using Sensors to Trouble Shoot .............................................. 5-17

Troubleshooting Electrical Problems ....................................... 5-18

If the Power Stops During Normal Operation .....................................5-18

Troubleshooting with the Status Light Panel .......................... 5-20

Network System Overview....................................................... 5-24

Connections to Servo Drives ..............................................................5-24

Symptoms and Possible Causes ............................................. 5-25

KVAL 995-H Operation/Service Manual

Table of Contents

1-1

KVAL 995-H Operation/Service Manual

CHAPTER 1 Introduction to the 995-H

This chapter provides an overview of the KVAL 995-H Routing and Hinge Application System.

Included is important safety Information and Lockout Tagout procedures.

Chapter 1 at a Glance

The following information is available in this chapter:

TABLE 1- 1. Summary of Chapter

Section Name Summary Page

Overview of the 995-H System This section provides an overview of the machine.

It includes a general description and a table of

available options

page 1-2

Safety First! IMPORTANT safety information is described in

this section

page 1-4

Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-8

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 specification plate

tor provide to KVAL, service center hours, and

return procedures

page 1-13

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

machine.

page 1-19

Overview of the

KVAL 995-H Operation/Service Manual

1-2

Overview of the

KVAL's 995-H is the perfect marriage of our high-speed mortising and Hinge installation with the

additional flexibility to machine 6'-8" and 7'-0" jambs for three hinges and 8'-0" jambs with four

hinges.

The 995-H is equipped with the Kval Three Shooter Screw gun, which is supported on ball bear-

ing equipped steel wheels, is mounted on an overhead track that is precisely aligned to ensure the

hinge is properly positioned into the pocket at each hinge location.

The 995-H will also include special chipout blocks that in addition to reducing tearout on the edge

of the jamb will serve to align the hinge in the mortised pocket in the jamb at each hinge location.

To attach 4" x 4" hinges to the jamb. Screws are automatically sorted and fed four at a time to the

screw gun. Operator manually places the hinge onto a magnetic indexing fixture, and then rolls

and pivots the Three-Shooter into the “H” block at each hinge location to attach the hinges.

The 995-H is also equipped with a Pre-Drill System for Three Shooter. Pilot holes are drilled

simultaneously and hinge pockets are blown clean of any excess sawdust within four seconds fol-

lowing the hinge pocket routing sequence for hinge screw mounting holes.

Weatherstrip retaining brackets are supplied for each routing head. The brackets will push the

weatherstrip back to prevent it from being damaged when the hinge pocket is mortised.

SPECIFICATIONS

Footprint Size: 13-1/2'x 6'

Crated Dimensions: 186"L x 88"W x 67"H Shipping Weight: 3200 lbs.

{UL} Electrical panel is built according to Underwriter's

Options Available

Option Title Description

Option L: 1/4" and 5/8" Radius Hinge

Routing Capability

3 1/2" and 4” hinge pocket can be machined for 1/4" or

5/8" radius. (Requires tooling diameter change).

Option W: Hinge Stops for 6'8",7'0" and 8'0"

Jambs

This option is limited to certain hinge pocket locations.

~Consult with your KVAL sales representative.

Option Z2: Quick-Change Hopper for Three

Shooter

Screw changing hopper for 3-shooter allows for rapid

change of screw colors.

Overview of the

1-3

KVAL 995-H Operation/Service Manual

About this Manual

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

Integration Package includes the following:

Operation and Service Manual includes the following:

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

Operation Descriptions of how to power

machine line, and operator inter-

face user screens.

3System IT

Administration

Descriptions of the PLC system,

and computer system.

4Maintenance Maintenance steps for the machine

line

5Troubleshooting Troubleshooting tips and theory of

operation.

Safety First!

   



Safety First!

Safety Sheet Sign-Off Sheet

                  -

             -

                 

           

Safety Terminology of Labels

               -

              

       

        

 DANGER              

 WARNING             



 CAUTION             



Safety Guidelines

               

        

       

         

   Failure to do so can result in dam-

age to equipment and/or serious injury to personnel.

       

        

         

    

Training

Safety First!

1-5

KVAL 995-H Operation/Service Manual

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 1-9.

Compressed Air

Safety First!

   



   

    

  

     -

    

   

   



         

        

 still power on the top side of the disconnect switch

        

         -

    must be installed at all locations

          -

    

  

  

Electrical

     

      

        

        

     

 

Before Conducting Maintenance

Laser Warnings

           

  

Safety First!



   

       

      

       

     -

      

Compliance with Codes and Regulations

Other Hazard Control Action

Report a Hazard

Before You Report an Accident

           

       STOP -

       

     

       

       

         

      

Follow Your Company’s Safety Procedures

       

       -

  

Lockout-Tagout Guidelines

KVAL 995-H Operation/Service Manual

1-8

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

1-9

KVAL 995-H Operation/Service Manual

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.

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

Lockout Tagout Procedure

KVAL 995-H Operation/Service Manual

1-10

Lockout Tagout Air Supply

Start Maintenance

7. Once the locks and tags are in place and all personnel are clear, attempt to operate

the machine to ensure equipment will not operate.

8. Maintenance 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 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 locks and keys returned to the lockout center.

6. Turn all air valves to the OFF position and place a pad-

lock through the hole (see illustration below).

NOTE: Place your tag on the padlock, as per the

tagout guidelines.

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Kval 995-H Operation And Service Manual

Brand: Kval

Model: 995-H

Type: Operation And Service Manual

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Kval 995-H Operation And Service Manual

Kval 995-H Operation And Service Manual

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