Kval 950-3 Owner's manual

Innovation, Quality & Honesty

950-3 System

Reference

Published: 6/28/07

Proprietary Notice

This document contains confidential and trade secret information, which is proprietary to Kval, Inc.

(“Kval”), and is protected by laws pertaining to such materials. This document, the information in this

document, and all rights thereto are the sole and exclusive property of Kval, are intended for use by cus-

tomers and employees of Kval, and are not to be copied, used, or disclosed to anyone, in whole or in

part, without the express written permission of Kval. 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.

KVAL 2006 and 950-3 are trademarks of Kval, Incorporated.

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 Incorporated products,

contact the Customer Support department

• http://www.kvalinc.com/customer_service.html (lists all the representatives, including email

addresses and phone numbers)

• 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: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Friday

Parts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday

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

• Email: [email protected]

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 sugges-

tions for improvement to us[email protected]. (NOTE: This is not a way to get customer sup-

port. For that, please refer to the Customer Service contact information above.) Thank you!

979-2

CHAPTER 1 .................................................................................... Introduction 1

Safety First! ..........................................................................................................3

Safety Guidelines ........................................................................................3

Lock Out Procedure .......................................................................................3

To lock out the 950-3 ..................................................................................4

Lockout and Tagout Guidelines .....................................................................5

Follow the P-R-O-P-E-R lockout rule of thumb. ..........................................5

Zero-Energy Start-Up ..........................................................................................6

Zero-Energy State to Start-Up to Operating State .........................................6

Start-up ........................................................................................................6

Inspect .........................................................................................................6

Clean Up .....................................................................................................6

Replace Guards ...........................................................................................6

Check Controls ...........................................................................................6

Remove Locks ............................................................................................6

Perform Visual Checks ...............................................................................6

950-3 Special safety concerns ........................................................................9

Initial Set up .......................................................................................................11

Trubolt Wedge Anchor ..............................................................................11

INSTALLATION INSTRUCTIONS ........................................................11

Electrical Connections Overview .............................................................12

CHAPTER 2 ..................................................................................... Operation 13

Machine Tour .....................................................................................................15

Quick Start .........................................................................................................17

Turning the 950-3 On and Off ...........................................................................19

Powering Up the 950-3 ................................................................................19

Powering up the system includes: .............................................................19

To Power Up the 950-3 .............................................................................19

Powering Down the 950-3 ...........................................................................19

To Power Down the 950-3 ........................................................................19

Control Panel ....................................................................................................20

Foot Pedals .........................................................................................................21

Emergency Shutdown and Recovery .................................................................22

To Resume Normal Operation after an E-Stop .........................................22

How to insert a jamb in the machine: ................................................................23

Setting Hinge Locations ...............................................................................25

Setting Hinge Pocket Length .......................................................................26

Spacer Stop Pins .......................................................................................26

Router Travel Limits Switches. ................................................................27

Setting Hinge Pocket Inset ...........................................................................28

Setting Hinge Pocket Depth .........................................................................30

979-2

Changing Router Bits .........................................................................................31

INSTALLING A ROUTER BIT ...............................................................31

REMOVING THE ROUTER BIT ............................................................31

COLLET CHUCK CARE ...........................................................................31

Chipout Blocks .................................................................................................32

Installing a Chipout Block ...........................................................................32

CHAPTER 3 ................................................................................. Maintenance 35

Maintenance Schedule .......................................................................................36

Daily .............................................................................................................36

Weekly .........................................................................................................36

May and December Checkups .....................................................................36

Lubrication Requirements ..................................................................................37

Linear Bearings .........................................................................................37

Flange Bearing and Pillow Blocks ............................................................37

Approved Lubrication Products for Lubricators .......................................37

Grease Points ...............................................................................................39

CHAPTER 4 ............................................................................Troubleshooting 41

Troubleshooting the Air Cylinders ....................................................................42

Adjusting Cylinder Extension Speed: ..........................................................43

Adjusting Cylinder Retraction Speed: ........................................................43

Troubleshooting Electrical Problems .................................................................44

If the Power Stops During Normal Operation ............................................44

Troubleshooting with the Status Light Panel ...............................................45

Adjusting Limit Switches ........................................................................47

Warranty .............................................................................................................49

950-3 1

CHAPTER 1 Introduction

KVAL's 950-3 High-Speed Hinge Jamb Machine routs Jamb hinges pockets. Employing three 1-3/4 HP

routers, it can simultaneously machine pockets for three hinges. After jambs are manually placed into

position, all other operations are automatic. Capacity is 8 jambs per minute. Customer must supply

hinge centers. Installation, if required, can be done by a KVAL factory technician at additional cost.

Special Note: Minimum Hinge Centers are 38-1/2”.

SPECIFICATIONS

Footprint Size: 4-1/2'x 9'

Crated Dimensions: 136"L x 56"W x 57"H

Shipping Weight: 1,200 lbs.

Introduction

2950-3

Safety First!

950-3 3

Safety First!

The 950-3 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 damage to equipment and/or seri-

ous injury to personnel.

Safety Guidelines

In addition to the caution and warning labels affixed to the 950-3 system, follow the guidelines below to

help ensure the safety of equipment and personnel.

Lock Out 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 the 950-3 while it is powered down. During a lockout,

disconnect all power and shut off the air supply. Be sure to use the tag-out guidelines noted below.

Guideline Description

Safety Training 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.

Protective Gear Never operate the machine without proper eye and ear protection.

Compressed Air .

Electrical 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 electri-

cal power supplying this machine.

When opening the cabinet you must first turn off the discon-

nect switch. When the cabinet door is open there is still power

on the top side of the disconnect switch. All maintenance and

repairs to electrical circuitry should only be performed by a

qualified electrician.

Before Conducting

Maintenance

Prior to performing any maintenance, repairs, cleaning or when clearing jammed

debris, you must disconnect, tag-out and lock-out the electrical and air pressure sys-

tems. This should be done in accordance with the state and/or federal code require-

ments.

Compliance with

Codes and Regula-

tions

KVAL Inc. 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 regulations which apply in your geographic area.

Other Hazard Control

Action

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

safety regulation, it is your responsibility to immediately protect your employees

against any such hazard and bring the matter to our attention for review and correction,

if deemed advisable.

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.

The compressed air system connected to this machine should have a three-way air

valve for shut-off and pressure relief. The air supply line providing the pressure to this

machine also has a three-way air valve. All cylinders on the machine

are under high pressure and can be very dangerous when activated.

Before performing any maintenance or repairs on the machine, turn the

main air disconnect off. Lock-out and tag-out this connection.

Still has power

in OFF position

4950-3

To lock out the 950-3

1. Assess 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. Disconnect power.

NOTE:Always lock out electrical disconnects on both electrical cabinets

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 tag-

out guidelines below. (see picture below).

b. Turn the disconnect switch on the larger high-frequency 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

tag-out guidelines below

5. Turn the main air valve to the OFF position and place a

padlock through the hole (see illustration).

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

guidelines below.

6. Insure the machine will not operate.

7. When maintenance or repairs are completed, the person

who performed the work must ensure all tools, spare parts,

test equipment, etc., are completely removed and that all

guards and safety 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 into 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.

When multiple people are

working on the machine, each

person needs to have a lock on

the handle in the extra holes

provided.

Safety First!

950-3 5

Lockout and Tagout Guidelines

• Place a tag on all padlocks. On the tags, include your

name and date.

• These locks are only to be removed by the person

whose name is on the tag.

• If more than one person is working on the machine,

then each additional person places a lock and tag on

each disconnect.

• You may only remove your own lock and tag.

NOTE: When many people are working on the same

machine, a multiple lockout device is necessary.

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 establish, insure and achieve a zero-energy state

R ...... Re-check controls and test to ensure they are in the “OFF” position

6950-3

Zero-Energy Start-Up

Zero-Energy State to Start-Up to Operating State

Starting the equipment properly is just as important as the lock-out/tag-out procedure in terms of safety.

Start-up

• Inspect

• Clean up

• Replace guards

• Check controls

• Remove locks

• Perform visual checks

Inspect

When work is finished, the equipment must be inspected for proper adjustment before starting equip-

ment.

Clean Up

All materials and debris must be cleaned up. Any combustible materials or old parts used during repairs

must be cleaned up and/or properly disposed of.

Replace Guards

Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard

on, leave only that guard off.

Check Controls

Confirm that all switches are in the “OFF” position. In some cases, the machine can start automatically

when energy is restored.

Remove Locks

Each person must remove his or her own lock and tag. This will ensure operators 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 person-

nel alarm before starting the equipment. If your operation is more complex, having many pieces of

equipment and a lot of people, a comprehensive lock-out/tag-out procedure may involve additional

steps. You will need to ask your supervisor about these procedures. A specific lock-out procedure may

be posted at each machine. On larger or long-term maintenance or installation projects, the procedures

should be explained to all participants and a copy of the procedures should be posted on-site for the

duration of the work. Provisions which ensure protection during shift changes when contractor or out-

side help is used must also comply with the lock-out/tag-out procedures. Comprehensive lock-out/tag-

Zero-Energy Start-Up

950-3 7

out may use a gang box or other system to ensure that locks are secure and not removed without autho-

rization.

Remember, lock-out/tag-out procedures work because you are the only one with the key to your lock.

Proper lock-out/tag-out can save lives, limbs, and money. Help make your work environment safe for

yourself and your fellow workers. Be sure to follow the P-R-OP-E-R lock-out/tag-out procedures, and

that those around you do also.

YOUR LIFE MAY DEPEND ON IT.

8950-3

950-3 9

950-3 Special safety concerns

Pinch Points

Cutting hazard

10 950-3

All safety covers MUST be in place for safe operation.

Ear and eye protection must be

worn to insure personal safety

during operation of this machine.

Initial Set up

950-3 11

Initial Set up

Your new Kval machine arrives at your plant crated, banded, taped, with painted set collars on all

shafts, keeping all of the precision moving parts secure during shipping.

1. To protect against damaging the machine with the forklift, move the machine as close as possible to

the area where it will be stationed before removing it from the crate

2. Use caution when removing the machine from the crate. Any time the machine is lifted to remove the

skids, there is a chance that the machine could drop suddenly, which could damage the machine or

injure people near the machine.

3. Remove all painted set collars from the shafts. Almost every shaft on the machine has set collars to

secure the moveable assembly mounted to the shafts.

4. Remove any tape securing the various buttons, switches and knobs. Level your Kval machine by put-

ting metal shims underneath the corners of the base. Leave a clear shot from the bolt holes in the foot

pads to your shop floor.

5. Once the machine is level, anchor it to the floor so that it won't move across the floor during opera-

tion. Kval recommends a ½-inch Red Head, Trubolt anchor in each of the foot pads.

Trubolt Wedge Anchor

INSTALLATION INSTRUCTIONS

1.Drill a ½-inch hole, minimum of 6-inch depth. Clean hole.

NOTE: Kval recommends drilling completely through the slab. If in the

future the machine needs to be moved, remove the Red Head nut and

pound the bolt flush with the floor surface.

2.Assemble anchor with nut and washer so that the top of the nut is flush

with the top of the anchor. Drive anchor through material to be fastened so

that nut and washer are flush with surface material.

3.Expand anchor by tightening nut 3 to 5 turns (torque requirement 55 ft.

lbs. for a ½-inch Red Head Trubolt

12 950-3

Electrical Connections Overview

The main electrical power is connected to the disconnect, located in the electrical panel on the left side

of the machine.

The 950-3 requires single phase power. Refer to the plant layout diagram or the brass information plate

to determine the voltage required.

AC Neutral

AC Hot

950-3 13

CHAPTER 2 Operation

The following chapters explain normal operation of the 950-3.

Operation

14 950-3

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Kval 950-3 Owner's manual

Kval 950-3 Owner's manual

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