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Kval 990-HQ Service Manual

Pre-hanging door system
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Service Manual
Published: August 14, 2019
Innovation, Quality & Honesty
990-HQ Pre-Hanging Door System

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Summary of Contents for Kval 990-HQ

  • Page 1 Service Manual Published: August 14, 2019 Innovation, Quality & Honesty 990-HQ Pre-Hanging Door System...
  • Page 2 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.
  • Page 3 KVAL 990-HQ 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.
  • Page 4 KVAL 990-HQ Service Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction to the 990-HQ Chapter 1 Chapter 1 at a Glance.............. 1-1 Overview of the 990-HQ Door Hanging System ..... 1-2 About this Manual ..............1-4 Safety First!................1-5 Safety Sheet Sign-Off Sheet..............1-5 Safety Terminology of Labels..............1-5 Safety Guidelines..................1-5...
  • Page 6 Table of Contents Maintenance of the 990-HQ Chapter 3 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...
  • Page 7 Tapered Bearing Housings ..............3-20 Ball Screw Nut ..................3-21 Ball Screw Drive Assembly..............3-21 Pulley and Idler Shafts................3-22 Lubrication Points on the 990-HQ..........3-23 Feed System Lube Points..............3-23 Carriage Head Lube Points ..............3-25 Back Section Lubrication Points ............3-26 Servo Motor Drive Assembly Locations........3-28 Back Section Servo Motor Assembly..........3-28...
  • Page 8 Adjusting Cylinder Extend Speed ............4-17 Adjusting Cylinder Retraction Speed ..........4-17 Using Sensors to Trouble Shoot ..........4-18 Location of Sensors on 990-HQ ............4-18 About Switches and Sensors........... 4-19 Troubleshooting Electrical Problems ........4-21 If the Power Stops During Normal Operation........4-21 Troubleshooting with the Status Light Panel ......
  • Page 9 Notes:...

  • Page 10: Chapter 1 At A Glance

    Chapter 1 at a Glance Introduction to the 990-HQ CHAPTER 1 This chapter provides an overview of the KVAL 990-HQ Door Hanging System and important safety information to follow when operating the machine. Chapter 1 at a Glance Section Name...

  • Page 11: Overview Of The 990-Hq Door Hanging System

    Overview of the 990-HQ Door Hanging System Overview of the 990-HQ Door Hanging System The 990-HQ entry door pre-hanging system produces machined doors with one or two cylindrical locks and either three or four hinges attached to the door edge and hinge jamb. Hinges can be mounted with or without hinge pins inserted.
  • Page 12 Overview of the 990-HQ Door Hanging System hinge on the magnetic hinge blocks, pressing a button shifts the center and right guns laterally, then all three guns travel downwards and index into “H” block fixtures at each hinge location, and fasten the hinges simultaneously.

  • Page 13: About This Manual

    Service Manual Chapter Title Description Chapter 1 System IT Brief description of Computer and PLC in the Machine Chapter 2 Maintenance Maintenance steps for the machine line Chapter 3 Trouble Shooting Troubleshooting tips and theory of opera- tion. 990-HQ Service Manual...

  • Page 14: Safety First

    See “Safety Sign-Off Sheet” on page 1-19. Safety Terminology of Labels In addition to the nameplate, KVAL machines may have other warning labels or decals that pro- vide safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.
  • Page 15 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 1-10. 990-HQ Service Manual...
  • Page 16 This should be done in accordance with applicable state and/or federal code requirements. Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions. 990-HQ Service Manual...
  • Page 17 Safety First! Compliance with Codes and Regulations 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.

  • Page 18: Lockout-Tagout Guidelines

    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 990-HQ Service Manual...

  • Page 19: Lockout Tagout Procedure

    Turn Switch to the Lock and Tag out Insert Lock into hole. OFF position Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided. 990-HQ Service Manual 1-10...

  • Page 20: Lockout Tagout Air Supply

    The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized. The tags must be destroyed and the locks and keys returned to the lockout center. 990-HQ Service Manual 1-11...

  • Page 21: Zero-Energy To Start-Up

    Replace Guards Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the KVAL Service team. See “Getting Help from KVAL” on page 1-14. Check Controls Confirm that all switches are in the “OFF”...
  • Page 22 Be sure to follow the P-R-O- P-E-R lockout/tagout procedures, and that those around you do also. Close the Cage Gate Verify all cage gates are securely closed. Ensure all safety protocols are in effect. 990-HQ Service Manual 1-13...

  • Page 23: Getting Help From Kval

    Ask about this procedure when calling are service team Product Return Procedure If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure below to return the machine or part.
  • Page 24 • With what equipment is the unit interfaced? • What was the application? • What was the system environment (temperature, spacing, contaminants, etc.)? Call Kval customer support for a Return Material Authorization (RMA). When you call: • Have the packing slip or invoice numbers available.

  • Page 25: How To Download The Service Application

    Download Application To download the application, go the KVAL website ( http:// www.kvalinc.com At the KVAL website, select the tab. Follow the instruc- Support tions on the Support web page. Click the Download button to download the application that...
  • Page 26 Session code: An internal number to track this machine. It is auto filled. Your Name Field: Enter your name. The KVAL techni- cian will use this field to identify this machine. Description: Enter machine Serial number and issue.
  • Page 27 How to Download the Service Application Page Intentionally Left Blank 990-HQ Service Manual 1-18...

  • Page 28: Safety Sign-Off Sheet

    Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the KVAL website (http:// www.kvalinc.com). You may also contact our Service Department at (800) 553- 5825 or email at service@kvalinc.com.
  • Page 29 Safety Sign-Off Sheet 990-HQ Service Manual 1-20...
  • Page 30 System IT Administration CHAPTER 2 This chapter describes the KVAL 990-HQ controller. The controller is an on board computer that supplies the user interface and controls the operation of the machine. With the controller, KVAL can remotely help troubleshoot your machine.

  • Page 31: About The 990-Hq Computer

    Support will be able to access your machine through your company’s Intranet and help solve any issues that may occur. Connection to the Intranet is achieved by interfacing with the 990-HQ con- troller. The location of the Intranet connection is identified in the figure below.

  • Page 32: Backing Up The Computer

    About Remote Connection to KVAL Service Remote access is a powerful tool to help fix issues that occur with the 990-HQ machine. With the remote access, our KVAL service technician is able to observe your user screen in real time, read ®...

  • Page 33: Network System Overview

    Figure 2- 2 below, shows the PLC connections in the 990-HQ. The PLC is located in the Main Electrical Panel. From the PLC, connections are made to coupler interfaces located near the sec- tions they control.

  • Page 34: Connections To Servo Drives

    Servo Drive 4 Servo Drive 3 Servo Drive 1 Servo Drive 2 2 High Voltage Outputs 2 High Voltage Outputs 2 High Voltage Outputs 2 High Voltage Outputs 2 High Voltage Outputs Servo Drives FIGURE 2- 3. 990-HQ Service Manual...

  • Page 35: High Frequency Panel Node Connections

    OK for hinge and plate routers, hinge P2P, and door width outputs to the stacker. For detailed wiring information, see your machine’s electrical drawings. Outputs Inputs Ether CAT Input (From Frame Node) Ether CAT Output (To E-Stop Circuitry) Coupler PLC Inter- face High Frequency Node FIGURE 2- 4. 990-HQ Service Manual...

  • Page 36: Frame Node Connections

    This node includes back section related inputs and outputs including, back section servos, face plate, boring, and door widths. For detailed wiring information, see your machine’s electrical draw- ings. Inputs Outputs 24 VDC PS 1 and PS 2 Back Section Node FIGURE 2- 5. 990-HQ Service Manual...

  • Page 37: Screw Driver Nodes 1-3

    Screw Driver related inputs and outputs. For general information, refer to Figure 2- 6 . For detailed wiring information, see your machine's electri- cal drawings. Inputs Screw Screw Screw Driver Node Driver Node Driver Node Outputs Screw Driver Nodes FIGURE 2- 6. 990-HQ Service Manual...
  • Page 38 Network System Overview 990-HQ Service Manual...
  • Page 39 This chapter describes preventative maintenance steps for KVAL 990-HQ. The content is geared to guide technicians to keep a regular maintenance schedule for your KVAL machine. Keeping your KVAL machine maintained is an important piece for successful operation of your door pro- duction process.

  • Page 40: Maintenance Schedule

    This should be done in accor- dance with applicable state and/or federal code requirements To view a video of the maintenance process, visit the KVAL website. Select the Video Tab to view videos. http://www.kvalinc.com/...
  • Page 41 Inspect Inspect all airlines for kinks or rubbing. Lubricate Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 standard hydraulic oil (KVAL PN:SYS-LUBEG). Lubricate Grease ball screw bearings (if applicable). See “Lubrication Schedule” on page 3-17.

  • Page 42: 300 Cycle Maintenance Steps

    Check vertical bearings for loose screws. Loose screws could cause bearing damage. High Dust Accumulation Areas Lock Bore Area: build up can occur and stop Bolt drill from extending. Front Section: Underneath Carriage Heads Jamb Clamp area. 990-HQ Service Manual...

  • Page 43: 600 Cycle Maintenance Steps

    Reverse action when installing trap. Inspect Tooling Inspect the Tooling for wear, (Drill Bits, Cutting Tools, Screw Driver Bits) See “Replacing Tooling in the Front Section” on page 3-32 see “Replacing Tooling in the Back Section” on page 3-37. 990-HQ Service Manual...

  • Page 44: Lubricate Inside Of Hopper

    Check and empty any dust collection units. Clean any dust filters. Dust collection systems vary from machine to machine. Follow manufacturers directions to empty dust collection units. Filters Dust Collection Containers Typical Dust Collection Unit FIGURE 3- 7. 990-HQ Service Manual...

  • Page 45: 3,000 Cycle Maintenance Steps

    • for kinks • cracks • wear from rubbing • Ensure tube clamps are tight Inspect all Photo Eyes Inspect all photo eyes secure and tight. Check Nut that attaches Photo Eye to Machine Check Connection to Photo Eye 990-HQ Service Manual...

  • Page 46: Inspect Limit Switches

    5 or 20 degrees before the limit switch actuates. Inspect Screw Receiver Parts Inspect screw receiver parts on six shooters for cracks or breaks. Inspect: Screw Receiver Spring Split Shell Steel Ring Rubber Ring Steel Ring Replace any parts that are broken. 990-HQ Service Manual...

  • Page 47: Inspect Airlines

    Refill Lubricators Ensure Air is turned off. Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 stan- dard hydraulic oil (KVAL PN: SYS- LUBEG). Slide locking switch down twist bowl and remove. Refill bowl. Reverse action when installing trap.

  • Page 48: Grease Ball Screw Bearings

    Grease ball screw bearings (if applicable). For a table of lubrication types to use, Lubrication Schedule. Clean Bearing Shafts Clean all bearing shafts with clean, dry cloth. Spray shaft with silicone oil and clean build up grime and dirt. 990-HQ Service Manual 3-10...

  • Page 49: 12,000 Cycle Maintenance Steps

    Inspect all air cylinders for air leaks. Replace the cylinder if seal is leaking. Symptoms include a cylinder not extracting or retracting to the limits. Cylinders not holding their position. Inspect Hydraulic Lines Inspect hydraulic lines for loose fittings, leaks and cracks. Inspect hydraulic lines from the source to the end assembly. 990-HQ Service Manual 3-11...

  • Page 50: Inspect Ball Rail Shafts And Ball Screws

    Clean and lubricate all slides and cylinder rods with dry silicone spray. Clean inside Hopper Clean inside hopper with dry sili- ® cone oil and a 3M ScotchBrite pad (or equivalent). Wipe dry with a clean dry rag 990-HQ Service Manual 3-12...

  • Page 51: 72,000 Cycle Maintenance Steps

    Note: It is recommend to back-up to an outside source (server, isolated drive, etc) on a schedule of your choosing. The KVAL service team would be happy to help. If any questions occur, contact our service team at (800) 553-5825 or at www.kvalinc.com.

  • Page 52: Wash Filter And Lubricator Bowls

    Wash filter and lubricator bowls with soapy water. • Slide lock down to unlock. • Twist bowl to remove it. • Remove filter from Air filter assembly. Inspect and clean or replace if necessary. • Clean bowls and reas- semble. 990-HQ Service Manual 3-14...

  • Page 53: Tool Changing Schedule

    Changing and inspecting the tooling on a regular basis keeps the door machining process running accurately and efficiently. KVAL recommends using the tables below for reference to change or inspect the machine tooling. Note: Depending on Machine or Option, some of these tools may vary.

  • Page 54: Maintenance No-Goes

    • Do not adjust any and all flow controls from factory settings • Do not remove shim stock • Do not Change or Alter any safety assemblies (E-Stops, Gate Locks, etc) • Do not Change programs in PLC’s or PC’s • Do not Alter Electrical Components 990-HQ Service Manual 3-16...

  • Page 55: Lubrication Schedule

    Lubrication Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 3-3. Type of Recommended Schedule Recommended Assembly Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...

  • Page 56: Lubrication Requirements

    Closed Pillow Block Hub Style Opened Pillow Block parallel perpendicular mount Greasing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N: Lube EP-2). Every 250 hours of operation. Pillow Block Bearings FIGURE 3-8. 990-HQ Service Manual 3-18...

  • Page 57: Flange Bearing Housings

    X,Y, or Z direction. Greasing Ball Rail Bearing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/ Every 250 hours N: Lube EP-2). of operation. Ball Rail Bearings FIGURE 3-10. 990-HQ Service Manual 3-19...

  • Page 58: About Taper Bearings

    To identify a , look at the enclosure and verify there are seals Tapered Bearing Housing between the screw and the housing. Tapered Bear- ing Housing Tapered Bear- ing Seals Tapered Bearing Housing FIGURE 3-12. 990-HQ Service Manual 3-20...

  • Page 59: Ball Screw Nut

    Ball Screw Drive Assembly. Ball Screw Nut Recommended every 80 Hrs Servo Motor Pillow Block (Hub Style Recommended every 250 Hrs Tapered Bearing Housing Recommend One Pump 4 times a Year Ball Screw Drive Assembly FIGURE 3-14. 990-HQ Service Manual 3-21...

  • Page 60: Pulley And Idler Shafts

    Note: It is important not to overfill the Idler Shaft. Avoid getting excess grease on the belts Grease Out Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease Idler Shaft (KVAL P/N: Lube Monthly EP-2). 990-HQ Service Manual 3-22...

  • Page 61: Lubrication Points On The 990-Hq

    Lubrication Points on the 990-HQ Lubrication Points on the 990-HQ This machine is a powerful electro-mechanical Caution motion control system. If servicing this machine, fol- low the safety guidelines. Failure to do so can result in damage to equipment and/or serious injury to person- nel.
  • Page 62 Lubrication Points on the 990-HQ Screw Drive Lubrication Points The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Lubrication Schedule” on page 3-17. Some Bearings are layered under plates. Use a Needle adapter to get...

  • Page 63: Carriage Head Lube Points

    Lubrication Points on the 990-HQ Carriage Head Lube Points Use an extender to reach tight areas. Make sure to Lockout/Tagout before maintenance. For rec- ommended greasing schedule, see “Lubrication Schedule” on page 3-17. Each Tool assembly includes 2 Pillow Block bear- ings aligned in the Z axis.

  • Page 64: Back Section Lubrication Points

    Lubrication Points on the 990-HQ Back Section Lubrication Points Use an extender to reach tight areas. Make sure to Lockout/Tagout before maintenance. For rec- ommended greasing schedule, see “Lubrication Schedule” on page 3-17. Bearings Back Section FIGURE 3- 17. 990-HQ Service Manual...
  • Page 65 Lubrication Points on the 990-HQ Bearings Back Section FIGURE 3- 18. 990-HQ Service Manual 3-27...

  • Page 66: Servo Motor Drive Assembly Locations

    Identify zerk fittings and apply EP-2 grease. Find the X, Y and Z axis rails to identify bearings. Some bearings may be difficult to get access to. Use an extender to reach tight areas. Make sure to Lockout/Tagout before maintenance. For recommended greasing schedule, see “Lubrication Schedule” on page 3-17. 990-HQ Service Manual 3-28...
  • Page 67 Servo Motor Servo Motor Servo Motor (X- Axis) (Z- Axis) (Y- Axis) Tapered Bearing Housing Tapered Ball Screw Pillow Block Bearing (Hub Style) Housing Ball Screw Nut Tapered Bearing Housing Front View of 990-HQ FIGURE 3-19. 990-HQ Service Manual 3-29...

  • Page 68: Description Of Air Input System

    Description of Air Input System Description of Air Input System There are two types of air inputs on KVAL machinery. Not all machines have lubricator option installed. Check your machine or Air prints to verify installation. Air Input with Lubrication The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine.

  • Page 69: Air Line Without Lubricator

    Usually 1 drop of oil every other cycle is a good rule of thumb. The approved list of oil for lubricators is as follows: • KVAL P/N SYSLUBG • Chevron AW Hydraulic Oil 32 • G-C lubricants light AW R&O •...

  • Page 70: Replacing Tooling In The Front Section

    Chisels: Upper and Chisels: Lower Upper and Right Lower Left Drill Motor CCW Router Motor Router Motor Location of Bits in the 990-HQ Heads FIGURE 3- 22. 990-HQ Service Manual 3-32...

  • Page 71: How To Access To Bit Assemblies

    Use a 17 mm shaft wrench and a 3/8 “collet wrench to remove the bit on the pre-drill or router assemblies. See Figure below. Inspect and clean collet assembly. 3/ 8 “Collet Wrench (PN: PERER16W 17 mm Shaft Wrench (PN: WRENCH17MM) Removing Pre-Drill or Router Bit. FIGURE 3-23. 990-HQ Service Manual 3-33...
  • Page 72 Router Depth to 2.0” Set to 1 3/4 “ 1 3/4 ““ 2.0 “ Bit Depth Gauge (PN432C) Setting the Bit Depths FIGURE 3-25. Tighten the collet assembly. Inspect and verify the work. Clean the work area. 990-HQ Service Manual 3-34...

  • Page 73: Remove And Replace The Chisels

    Pull the Six-Shooter assembly toward the machine-it will move slightly. Locate the back slide near the air valves (see images); push slide away from you. This allows for movement of the Six-Shooter assembly away from the machine 990-HQ Service Manual 3-35...
  • Page 74 Release holder to secure bit. Move Six-Shooter assembly back toward machine and pull the back slide toward you; then move assembly away from machine to restore assembly to original start- ing position 990-HQ Service Manual 3-36...

  • Page 75: Replacing Tooling In The Back Section

    Follow the instructions in this section to change the bits on th Bore Drill, Bolt Drill, and the Face Plate Router. Lock Bore Motor and Drill: Drills locks holes on the face of the door Bolt Drill Motor Machines Hole for Bolt Face Plate Motor and Drill: Routs face plate. 990-HQ Service Manual 3-37...

  • Page 76: Changing The Bore Drill

    Note: Make sure the arbor is not bottomed out in the back of the motor. If it is, the arbor will not tighten and will damage the collet or other machine parts. Note: The figure shows the cover off for training purposes. 990-HQ Service Manual 3-38...

  • Page 77: Changing The Bolt Drill

    3-40. Note: Make sure the arbor is not bottomed out in the back of the motor. If it is the arbor will not tighten and will damage the collet or other machine parts. 990-HQ Service Manual 3-39...

  • Page 78: Collet Torque Values

    Collet Torque Values Collet Torque Values KVAL recommends torquing the collets. Torquing adds consistency is important for repeatable machining. Follow the torque tool manufacturers method of torquing. 990-HQ Service Manual 3-40...
  • Page 79 Collet Torque Values 990-HQ Service Manual 3-41...

  • Page 80: Appendix: Conversion Chart

    Appendix: Conversion Chart Appendix: Conversion Chart 990-HQ Service Manual 3-42...
  • Page 81 Appendix: Conversion Chart 990-HQ Service Manual 3-43...
  • Page 82 CHAPTER 4 This chapter describes troubleshooting steps to help technicians solve issues that may occur with your KVAL machine. If help is needed, call or contact our KVAL Service team at (800) 553-5825 or http://www.kvalinc.com. Refer to the Air and Electrical drawings provided with delivery of the machine.

  • Page 83: About Motion Control

    KVAL Machinery. Sequencing: Sequencing is a series of events executed in a predetermined order. Most KVAL machines use a form of sequential motion control. A typical series of events for a KVAL machine are: Move the door into position.
  • Page 84 Positioning System: • Moves the load. Examples: A motor or a pneumatic cylinder. The Position Feedback. • Provides location information to the controller. Examples: A limit switch, a photo eye, or ferrous eye, a resolver or an encoder 990-HQ Service Manual...

  • Page 85: Troubleshooting Basics

    When did the problem first start? • At first Start-Up? • During the Run? When was the last calibration? Is the door true? Use Router Bit Depth Gauge (PN: 432C) to check depth of Bits Check tools for wear. 990-HQ Service Manual...

  • Page 86: Analyze The Sub Systems

    What Part of the Machine is not Working? Determine What: Check the Subsystems in the Table Below. What Subsystem is Respon- sible for the Failed Sequence Step. Typical KVAL Machine Sequence TABLE 4-1. Typical Machine Responsible Sub- Sequence system 1. Move Door into Posi-...
  • Page 87 • Bad Output: Relay may be stuck • Air Solenoid Valve: May be stuck or not working. Check the Positioning System Follow the circuit from the Controller output to the Load and check for compo- nent failures. 990-HQ Service Manual...

  • Page 88: About A Typical Contactor Control

    Control Circuit circuitry to the Common DC - Thermal Control Coil for OverLoad 120 Vac. Should measure Line Voltage here Motor Schematic Drawing of Contactor and Thermal Overload Block Diagram of a Common Contactor Circuit FIGURE4- 2. 990-HQ Service Manual...

  • Page 89: About Contactor Troubleshooting

    Rerun the machine and verify that motor runs without tripping the circuit. If the same overload keeps tripping, verify condition. Follow circuit path using the E-Drawing as a reference. a.Common issues: Check for bad wire, bad motor, or if load is too great for cur- rent draw. 990-HQ Service Manual...

  • Page 90: About Typical Vfd Motor Drive Control

    An adjustable-speed drive is used to control the motor speed and torque by varying motor input frequency and voltage. A variable-frequency drive (VFD) is used in KVAL machinery to accu- rately drive motors for machining or moving product through the machine. The figure below shows a block diagram of a typical motor drive circuit.

  • Page 91: About The Vfd

    Figure 4- 4 on page 4-9 VFD models vary in KVAL machines depending on where it is used, voltage requirements and type of PLC used. This is a general view on the VFD. See the machine’s Electrical Print for detailed information.

  • Page 92: About Vfd Troubleshooting

    Note: The number of reset buttons depends on the machine type and option. The fig- ure above shows a machine with 11 VFDs The VFD manuals are located in the Electrical Panels. On some machines, documentation can be found in the operation station in the documen- tation folder. 990-HQ Service Manual 4-11...

  • Page 93: About A Typical Pneumatic Circuit

    Note: In this sample set-up, Port A is nor- mally open and Port B is nor- mally closed. If power is OFF, air should be on Port B. Block Diagram of a Pneumatic Circuit FIGURE4- 7. 990-HQ Service Manual 4-12...

  • Page 94: Typical Pneumatic Assembly

    About a Typical Pneumatic Circuit Typical Pneumatic Assembly Pneumatic assembly setups vary in KVAL machines depending on where it is used and air requirements.This is a general overview of a pneumatic assembly. See the machine’s Air Print for detailed information.

  • Page 95: About Cylinder Operation

    Router applies the control voltage to the which directs com- Control Valve pressed air to extend port of the Cylinder are extended deactivating the Cylinder Router Retract Sensor fully extends activating the Router Extend Sensor. 990-HQ Service Manual 4-14...
  • Page 96 Control Valve Cylinder. retract deactivating the Cylinder Router Extend Sensor When the are fully retracted, the is activated. Cylinder Router Retract Sensor senses the voltage from the completing the process Retract Sensor 990-HQ Service Manual 4-15...

  • Page 97: Important Notice About Adjusting Cylinder Speed

    However, sometimes machine settling, mechanics be “broken in” may be cause to slightly adjust extend and retraction speed. If more than 1/2 turn on adjustment knobs are needed, call in a specialist or check with KVAL customer service at 1-800-553-5825. 990-HQ Service Manual 4-16...

  • Page 98: Adjusting Cylinder Extend Speed

    Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Tip: If Installing a new flow control assembly, shut down the flow control and back out 4 to 5 turns. this position is a good starting point for kine adjust. 990-HQ Service Manual 4-17...

  • Page 99: Using Sensors To Trouble Shoot

    • The distance from an eye to the door should be in range. Typically the range should be 3/4'' to 7/8'' from the top of all eyes to the door. Location of Sensors on 990-HQ Location and operation of sensors can be viewed by way of the See Chapter 2 of Status Screen.

  • Page 100: About Switches And Sensors

    PLC. When the metal object leaves the sensing area, the sensor to returns to 24VDC and sends it to the PLC. • As a result, if a metal object is sensed, the output of the sensor equals 0VDC Sensors on Piston and Cylinder 990-HQ Service Manual 4-19...
  • Page 101 The Limit Switch is activated by an assembly moving a switch arm. • .Depending on the model of limit switch, the amount of “pre-travel” (amount of movement from the arms resting position) is either 5 or 20 degrees before the limit switch actuates (Clicks). Switch Arm 990-HQ Service Manual 4-20...

  • Page 102: Troubleshooting Electrical Problems

    Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Panel. If copies NOTE: are unavailable, contact the KVAL Service Department. Have model number and serial number of machine readily available. Warning The following checks require the electrical panel to be energized.
  • Page 103 Note: Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain, blocked photo sensors etc.) Note: If a solenoid valve is suspected, and not cleared in the air checks section, it can be electrically jumped to check operation. 990-HQ Service Manual 4-22...

  • Page 104: Troubleshooting With The Status Light Panel

    STEP 4: Stop (Amber) If light is OFF go to item page 4-25. STEP 5: Start (Amber) If light is OFF go to item page 4-26. STEP 6: 24VDC (Green light is OFF go to item page 4-26. 990-HQ Service Manual 4-23...
  • Page 105 X1 and X2. If no power is measured it is a bad transformer. b.If there is power at X1 and X2, check the other side of the fuse. If now power, replace the fuse. 990-HQ Service Manual 4-24...
  • Page 106 Start button. If no voltage, check the Stop button to make sure it is all the way out and not stuck in, then check the contact to make sure it is closed. If still no voltage, check the wiring. 990-HQ Service Manual 4-25...
  • Page 107 Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block. Reinstall the (+ 24V positive) wires one by one, checking for +24VDC after installing each. If at any point no voltage is found trace the last reinstalled wire and check for shorts. 990-HQ Service Manual 4-26...
  • Page 108 Troubleshooting with the Status Light Panel 990-HQ Service Manual 4-27...
  • Page 109 30 as a remote access 3 priming 31 RJ45 connection 2 air line lubricator, maintenance schedule 17 KVAL, getting help 14 back section nodes inputs and outputs 7 ball screw, maintenance schedule 17 Beckhoff® CPU module 2 LCD display...
  • Page 110 35 sensors location on frame 18 troubleshooing 18 types 19 voltage levels 19 service connecting your machine to KVAL Service 3 service center, contacting information 14 servo drives connections location start light description 26 status light panel...
  • Page 112 Contacting KVAL Customer Service Phone and Fax: Mailing address: In the U.S and Canada, call (800) 553-5825 or fax Customer Support Department (707) 762-0485 Kval Incorporated Outside the U.S. and Canada, call (707) 762-7367 825 Petaluma Boulevard South or fax (707) 762-0485 Petaluma, CA 94952 Email: service@kvalinc.com...

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