The Lockout Tagout (LOTO) procedures for the KVAL 994-X are as follows:

1. Pre-Steps Before Lockout Tagout:
- Ensure all personnel are aware of the lockout process.

2. Lockout Tagout Power:
- Turn off all power sources and secure them with a padlock.
- Attach a tag to the padlock with the operator’s name and date.

3. Lockout Tagout Air Supply:
- Turn all air valves to the OFF position.
- Place a padlock through the hole and attach a tag as per tagout guidelines.

4. Start Maintenance:
- Verify that all locks and tags are in place.
- Attempt to operate the machine to confirm it will not start.
- Begin maintenance or repairs only after verification.

5. Post Maintenance Steps:
- Remove all tools, spare parts, and test equipment.
- Reinstall all guards and safety devices.
- Inspect the equipment to ensure it is safe to re-energize.

6. Zero-Energy to Start-Up:
- Remove the lock and tag (only by the person who placed them).
- Ensure the machine is safe before restarting.

If multiple people are working on the machine, each person must place their own lock and tag. Only the person who applied the lock can remove it.

This answer is automatically generated

Summary of Contents for Kval 994-X

Page 1 Innovation, Quality & Honesty 994-X Pre-Hanging Door System Operation and Service Manual Published: 11/20/2017...
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 994-X Operation/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 994-X Operation/Service Manual...
Page 5: Table Of Contents
Intro to the 994-X Door Hanging System Chapter 1 Overview of the 994-X Door Hanging System ......1-2 Available Options..................1-3 About this Manual .................1-5 Safety First!................1-6 Safety Sheet Sign-Off Sheet..............1-6 Safety Terminology of Labels..............1-6 Safety Guidelines..................1-6 Lockout-Tagout Guidelines ............1-10 Follow the P-R-O-P-E-R lockout rule of thumb........1-10...
Page 6 High Frequency Panel ................2-28 Description of the Six Light Panel ........... 2-29 About Sensors ................. 2-30 Quick Start ................2-31 Powering Operations for the 994-X ......... 2-33 How to Power Up the 994-X ...............2-33 Home the 994-X..................2-34 How to Power Down the 994-X............2-34 Emergency Shutdown and Recovery ..........2-35...
Page 7 Option SB: CNC Back Section Calibration .........3-19 System IT Administration Chapter 4 System IT Administration............4-2 About the 994-X Computer ..............4-2 Connections on the PLC...............4-2 Backing up the Computer ..............4-3 About Remote Connection to KVAL Service.........4-3 KVAL 994-X Operation / Service Manual...
Page 8 Maintenance of the 994-X Chapter 5 Maintenance Schedule ............5-2 300 Cycle Maintenance Steps ..........5-4 Clean, Clean, Clean!................5-4 600 Cycle Maintenance Steps ..........5-5 Check Air Gauges and Inspect Water Traps ........5-5 Inspect Tooling..................5-5 Lubricate inside of Hopper..............5-6 Empty Dust Collection Units ..............5-6 3,000 Cycle Maintenance Steps ..........
Page 9 Important Notice about Adjusting Cylinder Speed ......6-19 Adjusting Cylinder Extend Speed ............6-20 Adjusting Cylinder Retraction Speed ..........6-20 Using Sensors to Trouble Shoot ..........6-21 Location of Sensors on 994-X ..........6-22 Z Axis and Y Axis Front Section Sensors ...........6-23 KVAL 994-X Operation / Service Manual...
Page 10 Troubleshooting Electrical Problems ........6-25 If the Power Stops During Normal Operation........6-25 Troubleshooting with the Status Light Panel ........6-26 Network System Overview............6-31 Connections to Servo Drives ..............6-32 Connections to VFD’s (High Freq Panel)..........6-33 Symptoms and Possible Causes ..........6-34 994-X Door Hanging System...
Page 11: Table
CHAPTER 1 Intro to the 994-X Door Hanging System This chapter provides an overview of the KVAL 994-X Door Hanging System and important safety information to follow when operating the machine. Chapter 1 at a Glance TABLE 1- 1. Summary...
Page 12: Overview Of The 994-X Door Hanging System
1-1/2 hp Hi-Frequency spindle motor. The 994-X will accommodate doors with raised molding one or both sides up to 3/4" high, and a minimum of 4" between the raised molding and the edge of the door.
Page 13: Available Options
The track and the Six Shooter are precisely aligned to ensure the hinge is properly position into the pocket at each hinge location. Available Options For detailed information about available options, please contact our KVAL Sales and Service department. Option...
Page 14 Light will be mounted on the out-feed end of the 990-F4 that can be seen by the 700-C Assembly Table operator. The light will be on when the door in the 994-X is being machined as a right hand door and off for a left hand door.
Page 15: About This Manual
Overview of the 994-X Door Hanging System Option Title Description Narrow Door Support Supports doors between 12" - 16” Structure utilizes air cylinders and 7 pairs of industrial wheels for sup- port - mechanism is automatically put in and out of position via a...
Page 16: Safety First
See “Safety Sign-Off Sheet” on page 1-20. 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 17 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 1-11. KVAL 994-X Operation/Service Manual...
Page 18 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. KVAL 994-X Operation/Service Manual...
Page 19 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 20: 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 KVAL 994-X Operation/Service Manual 1-10...
Page 21: 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. KVAL 994-X Operation/Service Manual 1-11...
Page 22: 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. KVAL 994-X Operation/Service Manual 1-12...
Page 23: 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 1-15. Check Controls Confirm that all switches are in the “OFF”...
Page 24 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. KVAL 994-X Operation/Service Manual 1-14...
Page 25: 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 26 • 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 27: 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 28 Session code: An internal number to track this machine. It is auto filled. Your Name Field: Enter your name. The KVAL tech- nician will use this field to identify this machine. Description: Enter machine Serial number and issue.
Page 29 How to Download the Service Application Page Intentionally Left Blank KVAL 994-X Operation/Service Manual 1-19...
Page 30: 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 31 Safety Sign-Off Sheet KVAL 994-X Operation/Service Manual 1-21...
Page 32 Safety Sign-Off Sheet KVAL 994-X Operation/Service Manual 1-22...
Page 33 CHAPTER 2 Operation of the 994-X This chapter describes components, assemblies, and the user interface of the KVAL 994-X Door Hanging System. The content is geared to help operators understand the basic operation of the 994-X. Included are instructions to calibrate the machine and process a door.
Page 34: Operator's Tour
Operator’s Tour Operator’s Tour This section takes you on a tour of the 994-X Pre-Hanging Door machine. The manual breaks down the machine in sections and describes the assemblies located in that section. Options Available KVAL offers options to adapt to many factory processes. This manual describes many of the pop- ular options.
Page 35: Overview Of Machine
Valve Bank #3 Air Input: Fil- ter /Lubricator Hinge Carriage Lock Bore Assembly Shooter Hydraulic System Opt BC: Ball Catch Motor X2 8-Shooter Out-Feed Hopper Electrical Panel # 2 Identification of Key Assemblies of 994-X FIGURE 2- 1. KVAL 994-X Operation/Service Manual...
Page 36: Operator Controls
LH/ RH Door: Disable Auto Feed: Feed Mode: Select a Right Stops Door Feeding Chose Auto, Hand or Left Through OFF, or instant Hand Door feed thru Machine Controls FIGURE 2- 3. KVAL 994-X Operation/Service Manual...
Page 37: Door/Jamb Foot Pedal
Door Clamps: Two Clamps per Head. Can be Auto clamped and Manually clamped Jamb Stop Door Clamps Jamb Ledge Jamb Clamps: Two Clamps per Head. Manually clamped Jamb Stop Jamb Clamp Jamb Ledge Door and Jamb Clamps FIGURE 2- 4. KVAL 994-X Operation/Service Manual...
Page 38: In-Feed Section
Door through Sets and Lifts Eight machining process. the machine. Shooter out of Not shown: See “Opt N: Hinge pocket Weather Strip Brackets” on page 2-7. Key Assemblies on the In-Feed Section FIGURE 2- 5. KVAL 994-X Operation/Service Manual...
Page 39: Door Stops
Isolates Weather Strips during the routing process. A protective bar across top of H block keeps the strip up and away from the routers. Protective Bar: Keeps Jamb weather stripping from inter- fering with the machining pro- cess H Block: Carriage: KVAL 994-X Operation/Service Manual...
Page 40: Front Section
Hinge Carriage # 4 Hinge Carriage # 1 Hinge Carriage # 2 Hinge Carriage # 3 Standard: Pre Drill, Router Opt CR: adds CR Router Opt CH: adds Chisels, 4 corners View of Front Section FIGURE 2- 7. KVAL 994-X Operation/Service Manual...
Page 41: Hinge Carriage
The standard 994X utilizes automatic chip-out blocks that are clamped between the door and jamb to protect the door face and jamb edges from chipping during hinge routing. This option eliminates the chip-out blocks by adding four extra routers to the KVAL 994-X Operation/Service Manual...
Page 42 Opt CH: Chisel (Left) Pre-Drill: Opt CR: Counter Rotate Router: Standard Router Opt CH: Chisel (Right) Hinge Carriage Parts with added Option CH FIGURE 2- 9. KVAL 994-X Operation/Service Manual 2-10...
Page 43: Option: Securing Split Jambs
During process, press the button. Fire Side Nailer Note: The nail gun will not fire unless the enable button is activated on the Operators Screen and the safety switches are activated by the male split jamb KVAL 994-X Operation/Service Manual 2-11...
Page 44: About The Six /Eight Shooter System
Operator Controls Drive Assembly: • Air Motor • Gearbox • Six Screw Driver Bits Eight bits for Eight Shooter) Magnetic Indexing Fixture. Hinge is Placed Here Photo of Six Shooter on the 994-X FIGURE 2- 10. KVAL 994-X Operation/Service Manual 2-12...
Page 45: Option K: Eight Shooter
4 Door Screw applicators Indexing Fixture: Magnetic. Aligns screws and attaches the hinge to the door and jamb. The Eight shooter attaches 4 screws to the jamb and 4 to the door. Eight Shooter Parts FIGURE 2- 11. KVAL 994-X Operation/Service Manual 2-13...
Page 46: About The Six/Eight Shooter Controls
3-degree bevel front section. Just plunge the head and flip the trap out of position. This will allow the head to retract to the back position. Identify Controls on the Six/Eight Shooter FIGURE 2- 12. KVAL 994-X Operation/Service Manual 2-14...
Page 47: About The Hopper
Any adjustment may cause timing issues with the operation of the Six Shooter. If you think problems are being caused by the cylinders, please contact the KVAL Service Department for direction. Important: Do not put Magnetized Screws in Hopper. Magne- tized screws can cause sluggish response to screws getting stuck.
Page 48 ) moves upward to drain the rest of the screws out of the hopper this will Assembly cycle one more time to clear the screws from the slides. Press the button on the Six Shooter panel located mid machine on the front Reset section. Fill the Hopper with new screws. KVAL 994-X Operation/Service Manual 2-16...
Page 49: Driver Assembly
Factory set to align hinge. Latch Arm: Latch Arm Cylinder: Latches to H Block to secure in place. Moves latch arm in and out of position Six Shooter and Gear Box Call-Outs FIGURE 2- 14. KVAL 994-X Operation/Service Manual 2-17...
Page 50: Option: Quick Change Knuckle Assembly
To Use this Function: Flip the switch to activate the Solenoid. Place the wide knuckle hinge into the Hinge Appli- cator. See “Quick Start” on page 2-31 , for the procedure to apply hinge. KVAL 994-X Operation/Service Manual 2-18...
Page 51: About The Overhead Track
(Opt K) Eight Shooter Keep 6-Shooter in park and move the shooter down the machine Six Shooter: Keep 8- Shooter in park and move the shooter down the machine Over-Head Track FIGURE 2- 15. KVAL 994-X Operation/Service Manual 2-19...
Page 52: Option V: Narrow Door Support
Note: If machining both sides of the doors, flip the doors over to machine the other edge the doors. Ensure the doors are side by side as close to the original setup. Re perform steps 1 through 9. KVAL 994-X Operation/Service Manual 2-20...
Page 53: Back Section
‘X’ axis. on LH Door Ball Catch Shifts for 6’8'' to 8’0'' Door Feed Belt: Feeds Door through Machine Chip Out Location Lock Bore Motor and Drill: Drills locks holes on the face of the door KVAL 994-X Operation/Service Manual 2-21...
Page 54: Back View Of Rear Section
Bolt Drill Extend and Retract Cylinder Lock Bore Oil Reservoir Bolt Drill Motor: Machines lock plate on the side of the door Lock Bore Limit Switches Deep Face Plate Motor and Bit: Routs face plate. Shallow Retracted KVAL 994-X Operation/Service Manual 2-22...
Page 55: Opt Sb: Back View Of Rear Section
Back Section: Opt SB: Back View of Rear Section Opt SB: Adds a CNC Backsection with Corner Squaring The 994-X system combines very high quality hardware detailing, with high speed productivity. Unique features include computer con- trolled ball screw movements for all router and chisels, complete with square lock face plates.
Page 56: Opt Bc: Ball Catch Motors
(Out-Feed) on LH Door. Drills ball catch top edge (In- Adapts to 6’ 8'' and 8’ 0'' Feed) on RH Door doors. Ball Catch Cylinder: Moves motor assembly to 8’ 0'' or 6'' 8'' door position. KVAL 994-X Operation/Service Manual 2-24...
Page 57: Out-Feed
(Opt O) Air Blow off: next stage. Air Drop Six Shooter: Blows off dust from the door as it Feeds Out Sets and Lifts Six Shooter out of Hinge pocket Key Assemblies on the Out-Feed Section FIGURE 2- 16. KVAL 994-X Operation/Service Manual 2-25...
Page 58: Option O: Air Blow Off
Light is be mounted on the out-feed end of the 990-F4 that can be seen by the 700-C Assembly Table Operator. The light will be on when the door in the 994-X is being machined as a right hand door and off for a left hand door.
Page 59: About The Electrical Panels
About the Electrical Panels About the Electrical Panels The 994-X system includes a Main Electrical Panel and a High Frequency Panel. Figure 2- 17 below, is an overview of the location of assemblies in the panels. Warning: High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off.
Page 60: High Frequency Panel
Counter Rotate Router 1-4 (Opt CR) Contactors, Thermal Overload and Control Transformer Lock Bore Motor Bolt-Drill Motor 6- Shooter screw Driver In-Feed Ball Catch (Opt BC) Out-Feed Ball Catch (Opt BC) 8- Shooter Screw Driver (Opt K) FIGURE 2- 18. KVAL 994-X Operation/Service Manual 2-28...
Page 61: Description Of The Six Light Panel
Description of the Six Light Panel Description of the Six Light Panel The six lights on this panel indicate the status of the 994-X system. The Sequence that the lights activate is as follows: Control Power Overload Relay E-Stop Stop...
Page 62: About Sensors
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 KVAL 994-X Operation/Service Manual 2-30...
Page 63: Quick Start
Quick Start Quick Start Ensure factory air is present at the machine and the 994-X main air supply valve is turned on. Power up the 994-X. See “How to Power Up the 994-X” on page 2-33. Home the 994-X. See “Home the 994-X” on page 2-34.
Page 64 Six Shooter or pressing the Unclamp Jamb Clamp foot pedal. To continue, repeat from the load door section in this quick start. If completed, shut down the machine. See “How to Power Down the 994-X” on page 2-34 . KVAL 994-X Operation/Service Manual 2-32...
Page 65: Powering Operations For The 994-X
Powering Operations for the 994-X Powering Operations for the 994-X This section describes how to power up and to power down the 994-X. Powering up the system includes: • Applying power to the entire system • Starting the Control Circuit Powering down the system includes: •...
Page 66: Home The 994-X
The 994-X must go through a homing routine before any operations are performed. The homing routine sets a zero reference from which the 994-X measures its movement and cutting process. If power is lost or the 994-X is re-set, the homing routine must be performed again to reset the zero reference.
Page 67: Emergency Shutdown And Recovery
Powering Operations for the 994-X Emergency Shutdown and Recovery There are emergency shutdown (E-Stop) switches located at key points around the machine. Note: Depending on options of the machine, the E-Stop but- tons may be located at various locations. The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.
Page 68: Description Of User Interface Screens
Note: Use this information to isolate issues if having prob- lems with the machine. Controlling Access to User Screens The 994-X has the ability to lock out changes to certain parameters such a presets and calibra- tions. Note: Locked out parameters may vary due to customer design criteria.
Page 69: Menu Maps Of The Operator Screens
Width Adjust Jog Hinge Carriage #1 Door Stop / Clamp[ Jog Hinge Carriage #2 Skip Hinges Jog Hinge Carriage #3 Feed Control Jog Hinge Carriage #3 Burn Chipout Test Mode Exit Application Jog Lock Location KVAL 994-X Operation/Service Manual 2-37...
Page 70 Lower Right Chisel Pre-Drill Feed Sys timing Hinge Carriage Jamb Shelf Height Plate Fast Timers Plate Slow Timers See “About the Diagnostic Screen” on Diagnostics page 2-52. 990-H Log screen Total Door Count Daily Door Count KVAL 994-X Operation/Service Manual 2-38...
Page 71: About The Main Screen
About the Main Screen About the Main Screen The Main Screen is also the startup screen for the 994-X. From this screen, all the basic user inter- face controls are available to run a door. Main Screen FIGURE 2- 19.
Page 72 This button stops the door in the process. Shut Down System Button This button shuts down the computer. Use this button as part of the shutdown pro- cess.See “How to Power Down the 994-X” on page 2-34 Preset Selection Button Group Pressing a preset button, calls one of twelve presets stored in mem- ory.
Page 73 Fast Plate can be enabled or dis- Can Disable or enable the function (Option) led. Ball Catch shows the backset for each head. Lock Backset (Option) KVAL 994-X Operation/Service Manual 2-41...
Page 74 Auto Unclamping: Press to toggle auto Unclamping on or off. The Auto Unclamping auto unclamp button sets the machine to automatically unclamp the door after machining is completed. KVAL 994-X Operation/Service Manual 2-42...
Page 75: About The Setup Screens
About the Setup Screens Note: This section describes the menus in the Setup Screens. For information about performing calibration, ”. See “Chapter 2, Calibration of the 994-X Select the Button on the Main Screen to open access to the: Setup •...
Page 76 Vertical: The amount of time, in seconds, to give the vertical movement of the lock plate when in “Fast Plate” mode. Horizontal: The amount of time, in seconds, to give the horizontal movement of the lock plate when in “Fast Plate” mode. KVAL 994-X Operation/Service Manual 2-44...
Page 77: About The Setup Hinges 1-4 Screens
• Setup Hinge 1 • Setup Hinge 2 • Setup Hinge 3 • Setup Hinge 4 Chisels: Option CH only Counter Rotate Route r: Option CR only Hinge Setup Menu (1 of 3) FIGURE 2- 21. KVAL 994-X Operation/Service Manual 2-45...
Page 78 Use this to compensate for minor changes in tooling during calibration. Option CR: Chisel Adjustments These adjustments move Chisels in the X, Y, and Z direction. Use this to compensate for minor changes in tooling during calibration. KVAL 994-X Operation/Service Manual 2-46...
Page 79: About The Pre-Drill Screen
The number '0' entered in both X and Y are equal to no drill. Important: Never enter a negative number in the 'Y' parameter. The pre-drill will try to drill off the door into the Delrin. See the Figure on the next page. KVAL 994-X Operation/Service Manual 2-47...
Page 80 About the Setup Screens Sample of 4'' Hinge Dimensions 'X' Zero Point 'Y' Zero Point Sample of 3.5'' Hinge Dimensions 'X' Zero Point 'Y' Zero Point Pre-Drill Samples FIGURE 2- 23. KVAL 994-X Operation/Service Manual 2-48...
Page 81: About The Manual Operation Screens
From this screen, you can control certain functions of the machine in manual mode. This screen is mainly used in troubleshooting, checking cut specifications, and maintenance. Manual Operation Screen FIGURE 2- 24. Jog Carriage screen FIGURE 2- 25. KVAL 994-X Operation/Service Manual 2-49...
Page 82 Test Mode runs the hinge cycle, but does not extend the tools. This is primarily used to ver- ify a new template is correct and the hinge carriage will not bump into the H-Block or other assemblies. KVAL 994-X Operation/Service Manual 2-50...
Page 83 To stop, release the button Select the white box and enter the speed of the Speed: carriage. The range is 1% to 100%. Use the number pad to enter the desired speed and press OK when fin- ished. KVAL 994-X Operation/Service Manual 2-51...
Page 84: About The Diagnostic Screen
The top line will have the most current routine that is running. If the machine issue can not be resolved, call KVAL Inc. (1- 800-553-5825). Have any error code that is displayed, ready to give the KVAL representative.
Page 85: Option Sb: About The Cnc Back Section Operator Screens
The following is added to the in the CNC Back Section option. Main Screen Square Plate: Tog- gle to turn the square plate cutting routine ON or OFF Lock Plate: Adjust Lock Plate ti the X, Y and Z specifications KVAL 994-X Operation/Service Manual 2-53...
Page 86: Option Sb: Lock Calibration Screen
Option SB: Lock Calibration Screen Note: This section describes the menus in the Setup Screens. For information about performing calibration, ”. See “Chapter 2, Calibration of the 994-X The following screen is added in the CNC Back Section option. Chisels: Calibrates...
Page 87: Option Sb: Lock Access Buttons
Lock Access Button Access Tools (OFF): Lock Plate for easy access. with , Moves the out further if more Lock Access Button Access Tools (ON: Lock Plate room is needed to access tooling. • KVAL 994-X Operation/Service Manual 2-55...
Page 88 Option SB: About the CNC Back Section Operator Screens KVAL 994-X Operation/Service Manual 2-56...
Page 89 CHAPTER 3 Calibration of 994-X This chapter describes the steps to calibrate the 994-X, Door Pre-Hanging Machine. Chapter 3 at a Glance TABLE 3- 1. Section Name Summary Page The Benefits of calibration and when to calibrate. Page 3-2 About Calibration Specifications of the Calibration Routine.
Page 90: About Calibration
The KVAL 994-X has a built in Calibration routine to cut a horizontal slot with known parame- ters. The routine allows you to make the cut, measure, observe any anomalies, and help isolate to the component that causes the problem.
Page 91: Flow Chart Of Calibration
About Calibration Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the 994-X. Calibration Process Flowchart FIGURE 3- 1. KVAL 994-X Operation/Service Manual...
Page 92: About The Kval Calibration Routine
About the KVAL Calibration Routine About the KVAL Calibration Routine The calibration routine creates a reference cut to check settings against a “known good” source. The routine is used to verify the front section. It routes a horizontal slot and drills a center hole at precise specifications.
Page 93: Calibration Slot Drilling Specifications
About the KVAL Calibration Routine Calibration Slot Drilling Specifications The calibration routine will route a slot with known dimensions as a reference. The placement of the slot and the parameters of the cut can help in dialing in the calibration. Each tool in the Car- riage Head will be part of the slot drilling process.
Page 94: Run The Calibration Routine
Disables Hinge 2 of the hinges leaving one hinge enabled. Load the Door and Start the Cut Load the test door into the in-feed of the 994-X. Verify the setup and check for machine is safe to run. Press the button, to begin the process.
Page 95: Check Specifications Of The Front Section
‘Z” axis, the thumb represents the positive direction of the ‘Y” axis, then second finger represents the positive the direction of the ‘X’ axis. Either Front Section or Back Section Cuts Y Axis Positive movement Z Axis Positive movement X Axis Positive movement KVAL 994-X Operation/Service Manual...
Page 96: General Instructions To Adjust Parameters
Base: Keeps a Running Total of measured numbers entered. Sample of an Adjustment Menu FIGURE 3- 5. KVAL 994-X Operation/Service Manual...
Page 97: Step 1: Hinge Carriage Calibration
Check Specifications of the Front Section Note: KVAL suggests to follow the steps in the order below. Step 1 Verify and Adjust the Hinge Carriage Step 2 Verify and Adjust the Router and Counter Rotate Router Calibration Step 3 Verify and Adjust the Pre-Drill Calibration Step 4 Verify and Adjust the Chisels Calibration (Opt.
Page 98 Enter the offset in this box. Select the check mark to confirm this number and exit to go back to the Setup screen. Exit out of the Setup screen and rerun the Calibration test. Re-measure the parameters of slot. KVAL 994-X Operation/Service Manual 3-10...
Page 99 If the depth is too deep, enter a negative number of the difference of the measured and the desired depth. If the depth is too shallow, enter a positive number of the difference of the measured and the desired depth. Rerun tests until the correct depth is achieved. KVAL 994-X Operation/Service Manual 3-11...
Page 100: Step 2: Router Calibrations
X,Y and Z parameters. Router Calibration Menu FIGURE 3- 8. Repeat until cut is centered. Select the button to finish. Combine with Base Repeat until cut is centered. Click “Combine with Base” to finish. KVAL 994-X Operation/Service Manual 3-12...
Page 101: Step 3: Pre-Drill Calibration
Run the Calibration Routine. See “Run the Calibration Routine” on page 3-6. Check, measure, and calculate specifications of Pre-Drill cut. To set a new reference, go to the calibration menu and select Combine with Base Enter calculations. KVAL 994-X Operation/Service Manual 3-13...
Page 102 Z: To increase the depth, enter a positive value. To decrease the depth, enter a negative value. Pre-Drill Router Calibration Menu FIGURE 3- 9. Repeat until hole is centered. Select to finish. Combine with Base KVAL 994-X Operation/Service Manual 3-14...
Page 103: Step 4: (Option Ch) Chisel Calibration
Upper Left Chisel Chisel Jamb Door Lower Left Lower Right Chisel Chisel Adjusting the Chisels Identify the corner or comers to be calibrated. a.Upper Left Chisel b.Upper Right Chisel c.Lower Left Chisel d.Lower Right Chisel. KVAL 994-X Operation/Service Manual 3-15...
Page 104 Click the “Combine with Base” button to combine the two numbers to create refer- ence. KVAL 994-X Operation/Service Manual 3-16...
Page 105: Calibration Of The Back Section
Calibration of the Back Section Calibration of the Back Section For the 994-X, there are two screens available to calibrate the back section. To calibrate, follow the directions in “Enter a Positive or Negative Number?” on page 3-7 From the select -->...
Page 106: Fast And Slow Lock Plate Timing
Note: Before adjusting the Slow Lock Plate Timing, make sure the Fast Plate Routine is set properly adjusted. If the settings are in adjust the Extend Time, Slow Lock Plate Timing. Fast and Slow Lock Plate Timing Menu FIGURE 3- 12. KVAL 994-X Operation/Service Manual 3-18...
Page 107: Option Sb: Cnc Back Section Calibration
Enter a positive or negative number to move the tool in the desired direction. Moves Tool Set Z: Positive number Positive moves tools in, negative Number number moves tools out Positive Negative Negative Number Number Number KVAL 994-X Operation/Service Manual 3-19...
Page 108 Note the Positive # Negative # measurement value. Chisel Calibration (Back Section) These adjustments move Chisels in the X, Y, and Z direction. Use this to compensate for minor changes in tooling during calibration. KVAL 994-X Operation/Service Manual 3-20...
Page 109 Enter a positive or negative number to move the tool in the desired direction. Upper Upper Left Right Lower Lower Right Left Positive Positive number Number moves tools in, nega- tive number moves Negative Negative Positive tools Number Number Number KVAL 994-X Operation/Service Manual 3-21...
Page 110 Calibration of the Back Section KVAL 994-X Operation/Service Manual 3-22...
Page 111 CHAPTER 4 System IT Administration This chapter describes the KVAL 994-X 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 112: About The 994-X 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 994-X con- troller. The location of the Intranet connection is identified in the figure below (RJ45 to Intranet.) About the 994-X Computer ®...
Page 113: Backing Up The Computer
About Remote Connection to KVAL Service Remote access is a powerful tool to help fix issues that occur with the 994-X machine. With the remote access, our KVAL service technician is able to observe your user screen in real time, read ®...
Page 114 System IT Administration KVAL 994-X Operation/Service Manual...
Page 115 CHAPTER 5 Maintenance of the 994-X This chapter describes preventative maintenance steps for KVAL 994-X 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 production process.
Page 116: 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 117 Inspect Inspect all airlines for kinks or rubbing. Lubricate Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 stan- dard hydraulic oil (KVAL PN:SYS-LUBEG). Lubricate Grease ball screw bearings (if applicable). Clean Clean all bearing shafts with clean, dry cloth.
Page 118: 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 Car- riage Heads Jamb Clamp area. KVAL 994-X Operation/Service Manual...
Page 119: 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 5-21 see “Replacing Tooling in the Back Section” on page 5-26 KVAL 994-X Operation/Service Manual...
Page 120: 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 5- 14. KVAL 994-X Operation/Service Manual...
Page 121: 3,000 Cycle Maintenance Steps
• 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 KVAL 994-X Operation/Service Manual...
Page 122: 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. KVAL 994-X Operation/Service Manual...
Page 123: 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 124: Grease Ball Screw Bearings
Grease ball screw bearings (if applicable). For a table of lubrication types to use, Lubrication Schedule. For locations to lubricate, See Ball Screws (If Applicable) Clean Bearing Shafts Clean all bearing shafts with clean, dry cloth. Spray shaft with silicone oil and clean build up grime and dirt. KVAL 994-X Operation/Service Manual 5-10...
Page 125: 12,000 Cycle Maintenance Steps
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. KVAL 994-X Operation/Service Manual 5-11...
Page 126: Inspect Ball Rail Shafts
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 KVAL 994-X Operation/Service Manual 5-12...
Page 127: 72,000 Cycle Maintenance Steps
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. KVAL 994-X Operation/Service Manual 5-13...
Page 128: 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 129 Tool Changing Schedule Screw Receiver and 6-Shooter Tooling Screwdriver Bits 1,500 cycles Steel Rings 7,500 cycles Rubber Rings 7,500 cycles Screw Receivers 30,000 cycles Split Shells 30,000 cycles Springs 30,000 cycles KVAL 994-X Operation/Service Manual 5-15...
Page 130: 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 KVAL 994-X Operation/Service Manual 5-16...
Page 131: Lubrication Schedule
Lubrication Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 5- 3. Type of Assembly Recommended Schedule Recommended Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...
Page 132: Lubrication Requirements
If the bearing is equipped with a grease fitting (Zerk Fitting), it should receive 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N Lube EP-2) every 250 hours of operation. Note: Bearings without grease fittings have been pre-lubricated at the factory and do not require further lubrication.
Page 133: Gear Motor Lubrication Requirements
MOBILUBE HD 80 W-90 or equivalent. Ball Screws (If Applicable) All ball screws should be lubricated Dura-Lith Grease (KVAL P/N Lube EP-2) for every 80 hours of operation. At each lubrication grease should be pumped into the fitting until clean grease comes out around the ball screw.
Page 134: Adjusting The Air Line Lubricator
Repeat this same procedure for the back section and other trouble areas. It is recommended to check the lines every week to two weeks. KVAL 994-X Operation/Service Manual 5-20...
Page 135: Replacing Tooling In The Front Section
Option CH Pre Drill: Counter Rotate Router: Router: Standard Chisels: Two chisels per assembly. Square off Jamb and Door hinge cuts. Location of Bits in the 990-H Heads FIGURE 5- 18. KVAL 994-X Operation/Service Manual 5-21...
Page 136: 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. 3/ 8 “Collet Wrench (PN: PERER16W 17 mm Shaft Wrench (PN: WRENCH17MM) Removing Pre-Drill or Router Bit. FIGURE 5. 19. KVAL 994-X Operation/Service Manual 5-22...
Page 137 Set to 2.0” Set to 1 3/4 “ 1 3/4 ““ 2.0 “ Bit Depth Gauge (PN432C) Setting the Bit Depths FIGURE 5. 21. Tighten the collet assembly. Inspect and verify the work. Clean the work area. KVAL 994-X Operation/Service Manual 5-23...
Page 138: 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 KVAL 994-X Operation/Service Manual 5-24...
Page 139 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 KVAL 994-X Operation/Service Manual 5-25...
Page 140: Replacing Tooling In The Back Section
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. KVAL 994-X Operation/Service Manual 5-26...
Page 141: Changing The Bolt Drill
Collet Torque Values 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. KVAL 994-X Operation/Service Manual 5-27...
Page 142: 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. KVAL 994-X Operation/Service Manual 5-28...
Page 143 Collet Torque Values KVAL 994-X Operation/Service Manual 5-29...
Page 144 Collet Torque Values KVAL 994-X Operation/Service Manual 5-30...
Page 145 Troubleshooting the 994-X 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 146: 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 147 • 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 KVAL 994-X Operation/Service Manual...
Page 148: Typical Positioning Systems
Should measure Relay Line Voltage here Power Input Control Contactor (Coil) Input 120 VAC Power Output Should measure DC - Control Circuit Line Voltage here Common Motor Block Diagram of a Common Contactor Circuit FIGURE6- 24. KVAL 994-X Operation/Service Manual...
Page 149 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. The figure below shows a block diagram of a typical motor drive circuit with typical voltages.
Page 150 Should have High Pressure air here Output Input Control Control (Coil) Valve Input Output Should have High Control Circuit Pressure air on Common Activated Output Cylinder Cylinder Extended Retracted Block Diagram of a Pneumatic Circuit FIGURE6- 26. KVAL 994-X Operation/Service Manual...
Page 151: Troubleshooting Basics
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. Check back side of “H” blocks for sawdust build-up, which may affect depth. KVAL 994-X Operation/Service Manual...
Page 152: Analyze The Sub Systems
• Is the Load “bound up? • Is there sufficient lubrication? • Is it an alignment issue? • Is anything damaged? Check the Position Feed Back. • Does the Position Feed Back agree with the Load position? KVAL 994-X Operation/Service Manual...
Page 153 • Photo Eye: Bad element or bad cable • Limit Switch: Stuck, or failure • Wiring: Broken, worn insulation • PLC: Bad input port. Check the Positioning System Follow the circuit from the Controller output to the Load and check for component failures. KVAL 994-X Operation/Service Manual...
Page 154: About A Typical Contactor Control
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 FIGURE 6- 27. KVAL 994-X Operation/Service Manual 6-10...
Page 155: About Contactor Troubleshooting
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. KVAL 994-X Operation/Service Manual 6-11...
Page 156: 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 157: About The Vfd
Figure 6- 29 on page 6- 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 158: 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. KVAL 994-X Operation/Service Manual 6-14...
Page 159: 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 FIGURE 6- 32. KVAL 994-X Operation/Service Manual 6-15...
Page 160: 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 161: 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. KVAL 994-X Operation/Service Manual 6-17...
Page 162 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 KVAL 994-X Operation/Service Manual 6-18...
Page 163: 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. KVAL 994-X Operation/Service Manual 6-19...
Page 164: 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. KVAL 994-X Operation/Service Manual 6-20...
Page 165: Using Sensors To Trouble Shoot
• Check the output voltages of the sensors in inactive mode.The voltage should effec- tively equal 24 VDC 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. KVAL 994-X Operation/Service Manual 6-21...
Page 166: Location Of Sensors On 994-X
Location of Sensors on 994-X Location of Sensors on 994-X Figure 6- 36 below, shows the sensor locations on the 994-X The “I” designation represents an input to the PLC and the “Q” designation represents an output from the PLC.
Page 167: Z Axis And Y Axis Front Section Sensors
Z-Axis Home Eye Z-Axis Reverse Crash Eye Z-Axis Forward Crash Eye Y-Axis Home Eye Y-Axis Reverse Crash Eye Y-Axis Forward Crash Eye Figure 6- 37 Section View of 994-X Y and Axis Sensors FIGURE6- 37. KVAL 994-X Operation/Service Manual 6-23...
Page 168: Axis Sensors Front Section
The sensors are located underneath the Heads X-Axis Home Eye X-Axis Reverse Crash Eye X-Axis Forward Crash Eye Bottom View of 994-X location of X Axis Sensors FIGURE6- 38. KVAL 994-X Operation/Service Manual 6-24...
Page 169: 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 170: Troubleshooting With The Status Light Panel
The Status Light Panel is located on the Electrical Panel. All six lights are illuminated when the system is in proper working order. The lights turn on in a sequence and will stop at the point where a fault is first detected. KVAL 994-X Operation/Service Manual 6-26...
Page 171 STEP 4: Stop (Amber) If light is OFF go to item D on Page 6-29. STEP 5: Start (Amber) If light is OFF go to item E on Page 6-30. STEP 6: 24VDC (Green light is OFF go to item F on Page 6-30. KVAL 994-X Operation/Service Manual 6-27...
Page 172 If no power on the output side, and there is power going into the top of the Control Transformer, replace the Control Transformer. If there is power at the Control Transformer, check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip. KVAL 994-X Operation/Service Manual 6-28...
Page 173 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. KVAL 994-X Operation/Service Manual 6-29...
Page 174 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. KVAL 994-X Operation/Service Manual 6-30...
Page 175: Network System Overview
Network System Overview Network System Overview A PLC controls the 994-X. The 994-X PLC can process multiple analog and digital inputs, and output arrangements. The system can handle extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.
Page 176: Connections To Servo Drives
2 High Voltage Servo Drive 3 2 High Voltage 2 High Voltage Outputs Servo Drive 2 Servo Drive 5 2 High Voltage Servo Drive 4 2 High Voltage Outputs 2 High Voltage Outputs Servo Drives FIGURE6- 40. KVAL 994-X Operation/Service Manual 6-32...
Page 177: Connections To Vfd's (High Freq Panel)
Network System Overview Connections to VFD’s (High Freq Panel) The VFD servos are located in the High Freq Electrical Panel. For detailed wiring information, see your machine’s electrical drawings. VFD’s are located in the High Frequency Panel. KVAL 994-X Operation/Service Manual 6-33...
Page 178: Symptoms And Possible Causes
Slide valve on screw drop cylin- Push Slide Valve On Screw Head will not der turned off. Un-jam Screw Slide Start Jammed Screw Re-adjust Limit Switch Arms Limit Switch Out of Adjustment Replace Fuses Bad Fuse KVAL 994-X Operation/Service Manual 6-34...
Page 179 Empty Hopper Put Screws in the Hopper Jammed Split Shells Disassemble the Screw Receiver Routers Not Moving Through Beams Not Lined Up Pick Up on the Last Router Car- Into Home Position riage to realign. KVAL 994-X Operation/Service Manual 6-35...
Page 180 Symptoms and Possible Causes KVAL 994-X Operation/Service Manual 6-36...
Page 181 2-44 lock location flange block bearing, maintenance schedule 3-17 5-17 path to hinge setup front section pre-drill key assemblies 3-13, 3-15, 3-20 slot dimensions front section status steps before feedback 2-36 KVAL 990-H Operation / Service Manual...
Page 182 KVAL, getting help 1-15 operator’s tour top view out-feed LCD display key assemblies 2-25 smart power supply overload relay light description 2-29 Left Hand Rule linear bearing, maintenance schedule 5-17 KVAL 990-H Operation / Service Manual...
Page 183 KVAL Service 5-17 service center, contacting information 1-15 battery location servo drives connections connections location location 6-32 power location in main electrical panel 2-28 lock out procedure 1-11 servo positions...
Page 184 2-50 Windows CE® operating system,about X-axis calibration routine illustration of adjustment 3-10 Y-axis calibration hinges 3-10 illustration of calibration 3-11 zerk fittings 5-18 locations 5-18 zero-energy start-up clean up 1-13 inspect 1-13 KVAL 990-H Operation / Service Manual...
Page 188 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...

Kval 994-X Operation And Service Manual

Chapter 1 Intro to the 994-X Door Hanging System

Chapter 2 Operation of the 994-X

Chapter 3 About Calibration

Chapter 4 System IT Administration

Chapter 5 Maintenance of the 994-X

Chapter 6 Troubleshooting the 994-X

Quick Links

Troubleshooting

Need help?

Questions and answers

Related Manuals for Kval 994-X

Summary of Contents for Kval 994-X

Table of Contents