Kval 979-2 Owner's manual

979-2

Innovation, Quality & Honesty

979-2 Miter

Trim Saw

System Reference

Published: 4/24/07

979-2

979-2 a

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 979-2 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!

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Proprietary Notice ..........................................................................................a

Contacting KVAL ..........................................................................................a

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

Overview of the 979-2 ...................................................................................1

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

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

Lock Out Procedure .......................................................................................4

To lock out the 979-2 ..................................................................................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

Execute Visual Checks ...............................................................................6

979-2 Guard Placements and Purpose .................................................................8

Initial Set up .........................................................................................................9

Trubolt Wedge Anchor .............................................................................10

INSTALLATION INSTRUCTIONS .......................................................10

Electrical Connections Overview ................................................................11

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

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

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

Turning the 979-2 On and Off ...........................................................................19

Powering Up the 979-2 ................................................................................19

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

To Power Up the 979-2 .............................................................................19

Powering Down the 979-2 ...........................................................................19

To Power Down the 979-2 ........................................................................20

Emergency Shutdown and Recovery ...........................................................20

To Resume Normal Operation after an E-Stop ............................................20

Modes .................................................................................................................21

Mechanical Set-up .............................................................................................22

Presets ................................................................................................................24

Quick Access preset selection ...................................................................24

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Direct Access preset selection ..................................................................25

Preset Storage ...............................................................................................26

Manual Length Entry ...................................................................................27

Touch Screen Interface ......................................................................................29

OK TO MOVE .............................................................................................29

Run Screen ...................................................................................................30

Preset Screen ................................................................................................31

Length / Preset Screens ................................................................................32

Keypad Fractional Screen ............................................................................33

Keypad Quantity Screen ..............................................................................33

Length Only Screen .....................................................................................34

Machine Data ...............................................................................................35

Clamp Setup .................................................................................................36

CHAPTER 3 Calibration ...................................................................................37

CHAPTER 4 Maintenance .................................................................................39

Maintenance Schedule .......................................................................................40

Daily .............................................................................................................40

Weekly .........................................................................................................40

May and December Checkups .....................................................................41

Lubrication Requirements ..................................................................................42

Linear Bearings .........................................................................................42

Flange Bearing and Pillow Blocks ............................................................42

Approved Lubrication Products for Lubricators .......................................42

Gear Motor Lubrication Requirements .....................................................42

Ball Screws ...............................................................................................42

Adjusting the Air Line Lubricator (not available on all machines) ..........43

Grease Points ...............................................................................................44

Main Frame Bottom View ........................................................................44

Fixed Head ................................................................................................45

Movable Head ...........................................................................................46

Cut Depth Set-up ...............................................................................................47

Adjusting the Saw Height ............................................................................47

Feed Cylinder replacement and Feed Dog Adjustment procedure ....................53

CHAPTER 5 Troubleshooting ............................................................................57

Troubleshooting the Air Cylinders ....................................................................58

Adjusting Cylinder Extension Speed: ..........................................................59

Adjusting Cylinder Retraction Speed: ........................................................59

Troubleshooting Electrical Problems .................................................................60

979-2 e

If the Power Stops During Normal Operation ............................................60

Troubleshooting with the Status Light Panel ...............................................61

Adjusting Limit Switches ........................................................................64

Troubleshooting Photo Detectors .......................................................................65

Getting Help from Kval .....................................................................................66

Product Return Procedure ............................................................................66

Touch Screen Troubleshooting ..........................................................................67

Maintenance Screen .....................................................................................67

Machine Status ........................................................................................68

.....................................................................................................................68

Sequence does not complete .......................................................................69

Start Sequence (Feed) .................................................................................70

Saws do not extend .....................................................................................71

Saws do not start .........................................................................................72

Heads do not adjust .....................................................................................73

PLC Input-Bit Status ...................................................................................74

PLC Output-Bit Status ................................................................................75

.....................................................................................................................75

PLC M-Bit Status .........................................................................................76

GALIL IO Status .........................................................................................77

Kerf Saw Sequence (optional) ....................................................................78

Technical Support ........................................................................................79

Servo Trouble Shooting ...............................................................................80

Limit - Switch Timing .................................................................................81

General process description: .....................................................................81

979-2 X Axis Limit Switch Timing .............................................................82

Set Minimum Cut .........................................................................................83

Part Locations ....................................................................................................85

General Top View .....................................................................................85

Right or Movable Head .............................................................................86

Left or Fixed Head ....................................................................................87

Heads - Bottom View ...............................................................................88

Top View and Main Valve Bank ..............................................................89

Warranty .............................................................................................................91

f979-2

979-2 1

CHAPTER 1 Introduction

This chapter provides a description of the 979-2 product and identifies safety guidelines that you should

follow to ensure safety of personnel and equipment. Information includes:

• Overview of the 979-2

• Getting Started-Uncrating and Anchoring the 979-2

• Electrical Connections Overview

• Safety Guidelines

• Lock-Out Procedure

• Tag-Out Guidelines

• Zero-Energy Start-Up

• Zero-Energy State to Start-Up Operating State

• 979-2 Guard Placements and Purpose

Overview of the 979-2

The Kval Model 979-2 Miter Trim Saw is designed to cut door stops and casing materials up to 26

pieces per minute. Similar to a portable powered miter saw, the blades of the 979-2 cut from above the

work pieces through the material face to achieve the best quality possible with all types of moulding

materials, including pre-finished casing. Air consumption is just 8 CFM.

The hopper feed system accommodates material up to 4½ inches wide and from 12½ inches to 100

inches in length. The precision parallel feed system guarantees parallel indexing of work pieces under-

neath saw blades. Saw motors are three-phase, 3HP.

Saws pivot between either 0- or 90-degree positions. The CNC index system will automatically com-

pensate for cut length by adjusting the distance between saws.

Notable features of this machine are its touchscreen control panel and CNC index system.

All machine programming is done from the 979-2 operator's station touchscreen interface.

The touchscreen panel features on-board diagnostic screens that allow the operator to quickly and easily

identify the source of any errors or failures, even after they have occurred.

Operation Description

Trim material is placed in the hopper. The feed system then moves the material to the saws where the

end cuts are made. The material is then moved to the kerf saws (optional) and out of the machine.

Introduction

2979-2

Safety First!

979-2 3

Safety First!

The 979-2 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 979-2 system, follow the guidelines below to

help ensure the safety of equipment and personnel.

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.

Entering the Safety

Cage When the machine is on:

• Never reach hands beyond safety cage. Servo motors can unexpectedly

move quickly and out of control.

•Do not clear slugs out of the machine while it is running.

•Never perform any maintenance while machine is running.

•Never clean the machine while running.

•Never walk away from the machine while running.

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, or lock out the electrical and air pressure systems.

This should be done in accordance with the state and/or federal code requirements.

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.

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

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

machine also has a three-way air valve for the supply line. All cylinders

on machine are under high pressure and can be very dangerous when

activated. Before performing any maintenance or repairs on machine

turn the main air disconnect off. Lock out and tag out this connection.

Still has power

in OFF position

4979-2

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 979-2 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.

To lock out the 979-2

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 tagout

guidelines below. (see example 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

tagout guidelines below

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 regard-

ing the safe operation of this machine.

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!

979-2 5

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 tagout

guidelines below.

6.Once the locks and tags are in place and all personnel are

clear, attempt to operate the machine to ensure equipment

will not operate. When maintenance or repairs are com-

pleted, 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.

7.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.

8.The lock and tag can now be removed (only by the person(s) who placed them), and the machine can

be re-energized.

9.The tags must be destroyed and the locks and keys returned to the lockout center.

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 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.

• You may only remove your own lock and tag

NOTE: 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 insure they are in the “OFF” state

6979-2

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

• Execute 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 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.

Execute 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

979-2 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 employees. Make sure you follow the P-R-OP-E-R lock-out/tag-out proce-

dures, and that those around you do also.

YOUR LIFE MAY DEPEND ON IT.

8979-2

979-2 Guard Placements and Purpose

The following information gives a description of the mechanism being guarded, and the hazard being

guarded against.

1.Saw Assembly Guard:

Located on both saw carriages, covering the entire saw assembly. The saw assembly guard provides

protection from possible amputation, broken bones, eye injury from dust and wood particles, cuts, and

bruises. There are saw blade access doors on the back side of both guards. NEVER ACCESS SAW

BLADES WHILE POWER IS ON!

• Removal and Replacement:

There are four bolts securing each saw assembly guard. There are two bolts on the top of the

guard(s), and two bolts at the base of the guard(s) toward the end(s) of the machine. Removal of the

saw assembly guard is a two-person job. Never attempt to remove the guard by yourself.

2.Belt Guard:

Located on both saw carriages, INSIDE the saw assembly guard, toward the outboard front of the saw

assembly. The belt guard protects the operator from getting hands caught between the belt and the belt

pulleys. The guard provides protection from amputation, cuts, bruises, broken bones. NEVER ACCESS

THE BELT GUARD WHILE POWER IS ON!

• Removal and Replacement

There are two bolts securing each belt guard, located on the flange of the guard near the saw assem-

bly springs. Removal of the belt guard requires the operator to first remove the saw assembly guard.

3.Feed Assembly Guard:

Located on the inboard sides of both saw carriage feed dog assemblies. The feed assembly guard pro-

tects the operator from getting hands caught inside the moving parts of the feed assembly. The guard

provides protection against possible amputation, cuts, bruises, broken bones. NEVER ACCESS THE

FEED ASSEMBLY GUARD WHILE POWER IS ON!

• Removal and Replacement

There are eight socket heads securing bolts on each of the two feed assembly guards. The fastening

bolts are located in two rows of four bolts on the ends of the guard(s), toward the front and back of

the feed dog assembly.

4.Kerf Blade Guard (for optional Kerf Saw):

Mounted directly over the kerf blade(s) on both kerf routers located on either end of the 979-2. The

kerf blade guard is designed to protect the operator from the kerf blade, whether or not the machine is

operating. The kerf blade guard protects the operator from possible amputation, eye injury from air-

borne dust and wood particles, and cuts. NEVER ACCESS THE KERF BLADE GUARD WHILE

POWER IS ON!

• Removal and Replacement

The Kerf Blade Guard(s) is secured by two bolts on either side of the kerf blade guard.

NOTE: These guards are present only when the kerf saw option has been installed.

Initial Set up

979-2 9

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 operation.

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

10 979-2

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

Initial Set up

979-2 11

Electrical Connections Overview

Ground

M ain Panel

3-Phase in

p

ut

W ithout Kerf Saws With Kerf Saws

Single-Phase

HOT

(Black W ire)

Single-Phase

NEUTRAL

(

White Wire

)

3-Phase in

p

ut

M ain Panel D isconnect PLC

The main electrical power is connected to the disconnect,

located in the main electrical panel.

NOTE: The main electrical panel contains the PLC.

The 979-2 requires three phase power. Refer to the plant

layout diagram or the brass information plate to determine

the voltage required. If the 979-2 is equipped with kerf

saws, an additional 120-volt source is required.

Current Requirements:

• 220 volts - 20 amps

•460 volts - 10 amps

•120 volts - 22 amps (Kerf saws option only)

12 979-2

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Kval 979-2 Owner's manual

Kval 979-2 Owner's manual

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