Kval 990-FX Service Manual
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Kval 990-FX Service Manual

Pre-hanging door system with the rts-fx rotary hopper system
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Service Manual
Published: January 16, 2020
Innovation, Quality & Honesty
990-FX Pre-Hanging Door System
With the RTS-FX Rotary Hopper System

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Summary of Contents for Kval 990-FX

  • Page 1 Service Manual Published: January 16, 2020 Innovation, Quality & Honesty 990-FX Pre-Hanging Door System With the RTS-FX Rotary Hopper System...
  • Page 2 This Manual is confidential and contains proprietary information and intellectual property of KVAL Inc., and i s 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-FX 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 990-FX Operation/Service Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction to the 990-FX Chapter 1 Chapter 1 at a Glance.............. 1-1 Overview of the 990-FX Door Hanging System....... 1-2 Hopper Options..................1-2 Table of Available Options ..............1-3 About this Manual .................1-4 Safety First!................1-5 Safety Sheet Sign-Off Sheet..............1-5 Safety Terminology of Labels..............1-5...
  • Page 6 Pillow Block Bearing Housings ............3-18 Flange Bearing Housings ..............3-19 Ball Rail Bearing .................3-19 About Taper Bearings .................3-20 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-FX ..........3-23 KVAL 990-FX Operation Manual...
  • Page 7 To Replace the Front Section Chipout Block ......3-42 Summary of Burn Process..............3-42 Chipout Block Spacers................3-42 Procedure to change Front Chipout Block..........3-43 Collet Torque Values..............3-45 Troubleshooting the 990-FX System Chapter 4 About Motion Control ............... 4-2 Basic Control Circuit ................4-2 Troubleshooting Basics ............4-4 Before you Adjust .................4-4...
  • Page 8 Troubleshooting with the Status Light Panel ........4-19 Using Sensors to Trouble Shoot ..........4-24 Using Sensors to Trouble Shoot ............4-24 Location of Sensors on 990-FX ............4-24 Z Axis and Y Axis Front Section Sensors ...........4-26 X Axis Sensors Front Section .............4-27 Network System Overview............
  • Page 9 Notes:...

  • Page 10: Chapter 1 At A Glance

    Chapter 1 at a Glance CHAPTER 1 Introduction to the 990-FX This chapter provides an overview of the KVAL 990-FX 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-Fx Door Hanging System

    KVAL's 990-FX is the fastest and most productive pre-hanging system available in the industry. The 990-FX will rout a door and jamb for three or four hinges, drill pilot holes for the hinge screws, mortise for the lock, and apply three or (Opt four) hinges.

  • Page 12: Table Of Available Options

    Light will be mounted on the out-feed end of the 990-FX that can be seen by the 700-C Assembly Table operator. The light will be on when the door in the 990-FX is being machined as a right hand door and off for a left hand door.

  • Page 13: About This Manual

    Overview of the 990-FX Door Hanging System About this Manual This manual is part of a package delivered with the machine line. includes the following: Operation Manual Chapter Title Description Chapter 1 Introduction Descriptions of Machine Line and Safety Information.

  • 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 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. KVAL 990-FX 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. KVAL 990-FX 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 KVAL 990-FX 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. KVAL 990-FX 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. KVAL 990-FX 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. KVAL 990-FX Service Manual 1-13...

  • Page 23: Getting Help From Kval

    6:30 AM to 1:30 PM Pacific Standard Time, Friday • What is the extent of the failure/reason for return? What are the relevant error mes- sages or error codes? • How long did it operate? KVAL 990-FX Service Manual 1-14...
  • 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 tech- nician 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 KVAL 990-FX 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 KVAL 990-FX Service Manual 1-20...

  • Page 30: Chapter 2 System It Administration

    System IT Administration This chapter describes the machine controller. The controller is an on board computer that sup- plies the user interface and controls the operation of the machine. With the controller, KVAL can remotely help troubleshoot your machine. Chapter 2 at a Glance...
  • Page 31 KVAL Service 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-FX controller. The location of the Intranet con- nection is identified in the figure below (RJ45 to Intranet).

  • 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 Vision Line machine. With the remote access, our KVAL service technician is able to observe your user screen in real time, KVAL 990-FX Service Manual...
  • Page 33 System IT Administration read, and adjust programming code. For Vision Line access, the Intranet connection on the machine controller must have outside access to the Internet. KVAL 990-FX Service Manual...

  • Page 34: Chapter 3 Maintenance Of The 990-Fx

    CHAPTER 3 Maintenance of the 990-FX This chapter describes preventative maintenance steps for KVAL 990-FX. 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 35: 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 36 Inspect all nuts and bolts for tightnesses Tighten is necessary. Inspect Check that there is a smooth transition with a door feeding into and out of machine. Back-up Backup computer software. Clean Wash filter and lubricator bowls with soapy water. KVAL 990-FX Service Manual...

  • Page 37: 300 Cycle Maintenance Steps

    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. Typical Dust Collection Unit FIGURE 3- 1. KVAL 990-FX Service Manual...

  • Page 38: 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 Bits in the Front Section” on page 3-33 see “Replacing Tooling in the Back Section” on page 3-37 KVAL 990-FX Service Manual...

  • Page 39: 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 3-2. KVAL 990-FX Service Manual...

  • Page 40: 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 990-FX Service Manual...

  • Page 41: 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 990-FX Service Manual...

  • Page 42: 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 43: 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 Grease Ball Screw Bearings Clean Bearing Shafts Clean all bearing shafts with clean, dry cloth. Spray shaft with silicone oil and clean build up grime and dirt. KVAL 990-FX Service Manual 3-10...

  • Page 44: 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 990-FX Service Manual 3-11...

  • Page 45: 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 KVAL 990-FX Service Manual 3-12...

  • Page 46: 72,000 Cycle Maintenance Steps

    It is recommend to back-up to an outside source (server, isolated drive, etc) on a Note: 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. KVAL 990-FX Service Manual...

  • Page 47: 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. KVAL 990-FX Service Manual 3-14...

  • Page 48: 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 49: 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 990-FX Service Manual 3-16...

  • Page 50: Lubrication Schedule

    Lubrication Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 3-1. Type of Recommended Schedule Recommended Assembly Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...

  • Page 51: 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 3-3. KVAL 990-FX Service Manual 3-18...

  • Page 52: 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 3-5. KVAL 990-FX Service Manual 3-19...

  • Page 53: 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 3-7. KVAL 990-FX Service Manual 3-20...

  • Page 54: 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 3-9. KVAL 990-FX Service Manual 3-21...

  • Page 55: Pulley And Idler Shafts

    It is important not to overfill Note: 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). KVAL 990-FX Service Manual 3-22...

  • Page 56: Lubrication Points On The 990-Fx

    Lubrication Points on the 990-FX Lubrication Points on the 990-FX Feed System The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Lubrication Schedule” on page 3-17. Idler Shafts on the Pulleys in...
  • Page 57 Lubrication Points on the 990-FX Screw Driver 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 to hard accesses...

  • Page 58: Back Section

    Lubrication Points on the 990-FX Back Section The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Lubrication Schedule” on page 3-17. Back View Some Bearings are layered under plates. Use a Needle adapter to get to...

  • Page 59: Heads

    Lubrication Points on the 990-FX Heads The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Lubrication Schedule” on page 3-17. Assemblies shown transparent. Some Bearings are lay- ered under plates. Use a...

  • Page 60: Servo Motor Assembly

    Lubrication Points on the 990-FX Servo Motor Assembly The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Lubrication Schedule” on page 3-17. Sample Servo Motor Heads 1 and 2 Shift Assembly Option)

  • Page 61: Hubs

    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 Frame KVAL 990-FX Service Manual 3-28...
  • Page 62 Hubs Front Section Ball Catch Ball Catch L ocations FIGURE3- 15. KVAL 990-FX Service Manual 3-29...

  • Page 63: Jamb Transfer Grease Points

    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 KVAL 990-FX Service Manual 3-30...

  • Page 64: 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 65: Air Line Without Lubricator

    The air input system takes in shop air and supplies clean dry air (CDA). Shop Clean Dry Air (CDA) t Air Blow Off Input Air On- Off Knob Muffler Air Distribution Block Pressure Gauge with adjust Filter (purge) Air Filter without Lubricators FIGURE 3-17. KVAL 990-FX Service Manual 3-32...

  • Page 66: Replacing Bits

    This section describes the steps to change the pre-drill bits, router bits, and chisels in the heads on the front section, shows the locations of the replaceable parts inside the heads Router Bit Drill Bits Air Drive Router Motor Location of Bits in the 990-FX Heads FIGURE3- 18. KVAL 990-FX Service Manual 3-33...

  • Page 67: 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 3/ 8 “Collet Wrench 17 mm Shaft Wrench Removing Pre-Drill or Router Bit. FIGURE3- 19. KVAL 990-FX Service Manual 3-34...
  • Page 68 Drill Depth Router Depth Set to 2.0” Set to 1 3/4 “ 1 3/4 ““ 2.0 “ Router Bit Depth Gauge Setting the Bit Depths FIGURE3- 21. KVAL 990-FX Service Manual 3-35...

  • Page 69: Remove And Replace The Screwdriver Bits

    This allows for movement of the Six-Shooter assembly away from the machine. Move the Six-Shooter assembly away from the machine-it will move about 1½ inch. This provides room for hands to access the screwdriver bit holders. KVAL 990-FX Service Manual 3-36...

  • Page 70: Replacing Tooling In The Back Section

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

  • Page 71: Option Sb (Cnc Back Section)

    When loosening the collet, it may tighten up, crack again and con- tinue. Inspect and clean collet assembly. Insert the new bit into the assem- bly. Collet Wrench Shaft Wrench (1-5/8 '') (PN: 15-00-ER32) (PN: WRENCH026) KVAL 990-FX Service Manual 3-38...

  • Page 72: Changing The Bolt Drill

    3-45 Make sure the arbor is not bottomed out in the back of the motor. If it is the arbor Note: will not tighten and will damage the collet or other machine parts. KVAL 990-FX Service Manual 3-39...

  • Page 73: Chipout Block Replacement

    Chipout Block Replacement Chipout Block Replacement The 990-FX is a powerful electro-mechanical motion Caution control system. If servicing the 990-FX follow the Lockout/Tagout procedures described in Chapter1. Failure to do so can result in damage to equipment and/or serious injury to personnel.

  • Page 74: To Replace The Back Section Chipout Block

    Retaining Plates Retaining Bolt Hinge Carriage and all functions Location (X4) of the Lock except the Lock Bore. Burn the Chipout.See “Burn Chipout” on page 3-40 Run a test door to verify a clean cut. KVAL 990-FX Service Manual 3-41...

  • Page 75: To Replace The Front Section Chipout Block

    Chipout Block. Perform proce- dure. • Second Installation: Spacer to the back of the Chipout Block. Perform proce- dure • Stack the final Spacer Third Installation: to the back of the Chipout Block. Perform procedure KVAL 990-FX Service Manual 3-42...

  • Page 76: Procedure To Change Front Chipout Block

    6 flats of the bolt. Bottom View of Machine Location of Router Stop: Adjust when burn- ing the Chipout Block. Remove the old Chipout Block. Remove the 2 Bolts and Chipout Block for each Carriage Head. KVAL 990-FX Service Manual 3-43...
  • Page 77 Chipout. Ensure that the heads of the bolts do not rise above the surface of the Chipout when it is fully compressed. Adjust to 1/16'' Gap Run a test door to verify a clean cut. KVAL 990-FX Service Manual 3-44...

  • 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. KVAL 990-FX Service Manual 3-45...
  • Page 79 Collet Torque Values KVAL 990-FX Service Manual 3-46...
  • Page 80 Notes:...
  • Page 81 CHAPTER 4 Troubleshooting the 990-FX System 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. Note: Refer to the Air and Electrical drawings provided with delivery of the machine.

  • Page 82: 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 83 • 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 990-FX Service Manual...

  • Page 84: 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. KVAL 990-FX Service Manual...

  • Page 85: Analyze The Sub Systems

    Analyze the Sub Systems Check the Load for mechanical issues • Is the Load “bound up? • Is there sufficient lubrication? • Is it an alignment issue? • Is anything damaged? Check the Position Feed Back. KVAL 990-FX Service Manual...
  • Page 86 • 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. KVAL 990-FX Service Manual...

  • Page 87: 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 4- 23. KVAL 990-FX Service Manual...

  • Page 88: 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. KVAL 990-FX Service Manual...

  • Page 89: 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 90: About The Vfd

    Figure 4- 25 on page 4- 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 91: About Vfd Troubleshooting

    Note: The number of reset buttons depends on the machine type and option. The figure 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 990-FX Service Manual 4-11...

  • Page 92: 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 4- 28. KVAL 990-FX Service Manual 4-12...

  • Page 93: 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 94: 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 990-FX Service Manual 4-14...
  • Page 95 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 990-FX Service Manual 4-15...

  • Page 96: 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 990-FX Service Manual 4-16...

  • Page 97: 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 990-FX Service Manual 4-17...

  • Page 98: 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 99: Error Checking On The Variable Frequency Drives

    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 990-FX Service Manual 4-19...
  • Page 100 STEP 4: Stop (Amber) If light is OFF go to item on page 4-22. STEP 5: Start (Amber) If light is OFF go to item on page 4-23. STEP 6: 24VDC (Green light is OFF go to item on page 4-23. KVAL 990-FX Service Manual 4-20...
  • Page 101 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 990-FX Service Manual 4-21...
  • Page 102 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 990-FX Service Manual 4-22...
  • Page 103 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 990-FX Service Manual 4-23...

  • Page 104: Using Sensors To Trouble Shoot

    24 VDC Location of Sensors on 990-FX Figure 4- 33 below, shows the sensor locations on the 990-FX The “I” designation represents an input to the PLC and the “Q” designation represents an output from the PLC. KVAL 990-FX Service Manual...
  • Page 105 Screw Drive Head Out #3 Screw Drive Head In #3 Width Adjust- Width Adjust- ment Sensors ment Sensors Before Out Feed Stop Eye After Out Feed Stop Eye Location of Sensors Top View 990-FX FIGURE4- 33. KVAL 990-FX Service Manual 4-25...

  • Page 106: Z Axis And Y Axis Front Section Sensors

    Z-Axis Forward Crash Eye Hinge #3 Hinge #1 Hinge #2 Y-Axis Home Eye Y-Axis Reverse Crash Eye Y-Axis Forward Crash Eye Figure 4- 34 Section View of 990-FX Y Axis and Z-Axis Sensors FIGURE4- 34. KVAL 990-FX Service Manual 4-26...

  • Page 107: 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 Hinge #3 Hinge #2 Hinge #1 Bottom View of 990-FX location of X Axis Sensors FIGURE4- 35. KVAL 990-FX Service Manual 4-27...

  • Page 108: Network System Overview

    Network System Overview Network System Overview A PLC controls the 990-FX. The 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 109: Connections To Servo Drives

    2 High Voltage Outputs Servo Drive 3 Servo Drive 6 2 High Voltage Outputs 2 High Voltage Outputs Servo Drive 2 2 High Voltage Outputs Servo Drive 4 2 High Voltage Outputs Servo Drives FIGURE4- 37. KVAL 990-FX Service Manual 4-29...

  • Page 110: High Frequency Panel Node Connections

    • 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 Interface High Frequency Node Sample FIGURE4- 38. KVAL 990-FX Service Manual 4-30...

  • Page 111: Frame, Screw Driver, And Back Section Node Locations

    Screw Driver Nodes summery, these nodes include the following: • Six shooter inputs and outputs, • Hopper inputs and outputs, • Screw driver related inputs and outputs. For detailed wiring information, see your machine's electrical drawings. KVAL 990-FX Service Manual 4-31...

  • Page 112: Back Section Node

    Back Section Node includes the following: • back section related inputs and outputs • including, back section servos • lock plate • bore • door widths For detailed wiring information, see your machine’s electrical drawings. KVAL 990-FX Service Manual 4-32...
  • Page 113 Network System Overview KVAL 990-FX Service Manual 4-33...
  • Page 114 Network System Overview KVAL 990-FX Service Manual 4-34...
  • Page 115 1-10 connection to servo amplifiers power up troubleshooting 4-18 pre-drill bit flange block bearing, maintenance schedule 3-17 using tool to set depth 3-35, 3-39 KVAL 990-FX Service Manual...
  • Page 116 3-36 sensors location on frame 4-24 troubleshooing 4-24 x-axis and y-axis locations 4-26 service connecting your machine to KVAL Service servo drives connections location 4-29 start light description 4-23 status light panel description 4-19 use as troubleshooting key...
  • Page 120 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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