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Summary of Contents for Kval EP-1
- Page 1 Innovation, Quality & Honesty EP-1 Edge Prep Machine Operation and Service Manual Published: 1/23/15...
- 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 EP-1 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 EP-1 Operation/Service Manual...
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Page 5: Table Of Contents
Setting the Router Depth ..............2-10 Powering the EP-1 ..............2-12 How to Power Up the EP-1..............2-12 Machining a Door..............2-13 Move a Door into Position and Start Sequence ........2-13 How to Power Down the EP-1 ..........2-15 KVAL EP-1 Operation/Service Manual... - Page 6 Gear Motor Lubrication Requirements..........3-5 Description of Air Input System ............3-5 Adjusting the Air Line Lubricator............3-5 Priming the Air Line Lubricator .............3-6 Trouble Shooting the EP-1 Chapter 4 Adjusting Limit Switches ............4-2 Adjusting the Bolts on the Face Plate Turrets......4-3 Troubleshooting Electrical Problems ........
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Page 7: Chapter 1 At A Glance
CHAPTER 1 Introduction to the EP-1 This chapter provides an overview of the KVAL EP-1 Edge Prep Machine and important safety information for operating the machine. Chapter 1 at a Glance Chapter 1 at a Glance ..................1-1 Overview of the EP-1 .................. -
Page 8: Overview Of The Ep-1
Overview of the EP-1 Overview of the EP-1 KVAL's EP-1 Edge Prep Machine routs and bores a faceplate and latch hole. It uses lock holes bored by previous machinery as an index. About this Manual This Manual is includes identification of machine assemblies, power-up and power-down steps, operation and using the user interface. -
Page 9: Safety First
See “Safety Sign-Off Sheet” on page 1-15. 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 10 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 1-7. KVAL EP-1 Operation/Service Manual...
- Page 11 Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tag out, or lock out the elec- trical and air pressure systems. This should be done in accordance with applicable state and/ or federal code requirements. KVAL EP-1 Operation/Service Manual...
- Page 12 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.
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Page 13: Lockout Tagout Procedure
OFF position. Then pull out the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tagout guidelines below. KVAL EP-1 Operation/Service Manual... - Page 14 • If more than one person is working on the machine, then each additional person places a lock and tag on each disconnect. • Only each operator may remove their own lock and tag. KVAL EP-1 Operation/Service Manual...
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Page 15: Follow The P-R-O-P-E-R Lockout Rule Of Thumb
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 EP-1 Operation/Service Manual... -
Page 16: 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 “Contacting KVAL” on page 1-2. Check Controls Confirm that all switches are in the “OFF”... - Page 17 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. 1-11 KVAL EP-1 Operation/Service Manual...
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Page 18: Getting Help From Kval
Chapter 3 “System IT Administration” on page 3-1, for more information. 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 19 • 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 20 Getting Help from KVAL Page Intentionally Left Blank 1-14 KVAL EP-1 Operation/Service Manual...
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Page 21: Safety Sign-Off Sheet
It is recommended you make a copy of this sheet for new operators. If a copy is Note: 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 22 Safety Sign-Off Sheet 1-16 KVAL EP-1 Operation/Service Manual...
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Page 23: Operation Of The
Operation of the EP-1 This chapter describes components, assemblies, and the user interface of the KVAL EP-1 Edge Prep Machine. The content is geared to help operators understand the basic operation of the EP-1. Chapter 2 at a Glance Operator’s Tour .................... -
Page 24: Operator's Tour
Operator’s Tour Operator’s Tour This section takes you on a tour of the EP-1 machine. The figure below shows locations of selected areas, parts, and assemblies on the machine Factory Air Input Drill Cutting Head Air Bank Foot Pedals Electrical... - Page 25 Operator’s Tour Figure 2- 2 below, shows select EP-1 front section assemblies and controls. Cone Clamp Clamp Control Panel Foot Pedals Cone Alignment Router Door Clamp Start Sequence Front Section View FIGURE 2- 2. KVAL EP-1 Operation/Service Manual...
- Page 26 Operator’s Tour Figure 2- 3 below, shows a isolated view of the drill and router placement. Caution: Never reach your hands into this area unless the motors have stopped. Drill Router Drill and Router FIGURE 2- 3. KVAL EP-1 Operation/Service Manual...
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Page 27: About The Electrical Panel
Operator’s Tour About the Electrical Panel The EP-1 has a Main Electrical Panel located on back section of the machine. Refer the machine's electrical prints for in-depth information The Main Electrical Panel: • Supplies voltage to drill by way of the contactor and thermal overload circuit •... -
Page 28: Description Of The Six Light Panel
Operator’s Tour Description of the Six Light Panel The six lights on this panel indicate the status of the EP-1 system. Refer to the “KVAL EP-1 Service Manual” for information on using this panel Note: for troubleshooting. The Sequence that the lights activate is as follows:... -
Page 29: Quick Start
Ensure factory air is present at machine and the DL-NCD main air supply valve is turned on. Setup EP-1. See “Setup of the EP-1” on page 2-8 Power up the EP-1. See “How to Power Up the EP-1” on page 2-12 Running a Door. See “Machining a Door” on page 2-13 Power down the EP-1. -
Page 30: Setup Of The Ep-1
Setup of the EP-1 Setup of the EP-1 The EP-1 lock preparation machine can be set to automatically drill for the latch bore, and rout for the rectangular latch plate. Before machining the door, set up the machine to adapt to the door type. -
Page 31: Setting A 2 3/4" Or A 2 3/8" Backset
Setup of the EP-1 0° 3° Knob down Knob down 0° Stop 3° Stop Zero and Three Degree Adjustments FIGURE 2- 6. Setting a 2 3/4" or a 2 3/8" Backset Pull cone cylinder towards you. Rotate turret to desired backset and release cone cylinder. The longer bolt on turret is the 2 3/4"... -
Page 32: Setting The Face Plate Router For Vertical Travel
Router Turret Face Plate Adjustment FIGURE 2- 8. If both the plate and latch hole are off-center, contact KVAL for instructions on Note: shimming the self-centering clamp system. Setting the Router Depth Adjust the router depth for a 0° or 3° bevel door. Set the router depth to the appropriate settings. - Page 33 Setup of the EP-1 Rotate Turret 3 Degree 0 Degree Loosen Adjustment Bolts to move router Router Adjust FIGURE 2- 9. 2-11 KVAL EP-1 Operation/Service Manual...
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Page 34: Powering The Ep-1
Powering the EP-1 Powering the EP-1 This section describes how to power up and to power down the EP-1 Powering up the system includes: • Applying power to the entire system • Starting the Control Circuit Powering down the system includes: •... -
Page 35: Machining A Door
Machining a Door Machining a Door After power up of the EP-1, start the process to machine the door. Move switch on the control panel to Drill, Edge Prep Both, or Router. • Drill only drills the latch bore • Router routes only the faceplate •... - Page 36 After the process is complete, the cutting tools will retract and the door clamps will release. Move the door to the next process. To machine the next door, repeat step 1.through step 5. 2-14 KVAL EP-1 Operation/Service Manual...
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Page 37: How To Power Down The Ep-1
How to Power Down the EP-1 How to Power Down the EP-1 Press the from the Stop button to stop the machine. panel Push the CONTROL TRANS- switch into the OFF FORMER position. This kills power to the machine. All status lights should be off. - Page 38 How to Power Down the EP-1 2-16 KVAL EP-1 Operation/Service Manual...
- Page 39 CHAPTER 3 Maintenance of EP-1 This chapter describes preventative maintenance steps for KVAL EP-1. 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.
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Page 40: Maintenance Schedule
Maintenance Schedule Maintenance Schedule KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Refer to this section for steps to perform maintenance. Recommended Lubrication Schedule TABLE 3-1. Type of Assembly Recommended Schedule Recommended Lubrication Type Linear Bearing... -
Page 41: Six Month Checkups
Maintenance Schedule • Refill lubricator with an ISO 32 standard hydraulic oil (use KVAL part# SYS- LUBEG). Six Month Checkups • Wash filter and lubricator bowls with soapy water. • Grease all bearings and tighten all bolts. Access to some grease fittings is difficult and will require a special needle point grease tip (supplied with your system). -
Page 42: 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. Bearings without grease fittings have been pre-lubricated at the factory and do Note: not require further lubrication. -
Page 43: Gear Motor Lubrication Requirements
Once you have a steady flow, tighten knob back down until you have one drop per every other cycle. KVAL EP-1 Operation/Service Manual... -
Page 44: Priming 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 EP-1 Operation/Service Manual... -
Page 45: Trouble Shooting The
Trouble Shooting the EP-1 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. Chapter 4 at a Glance Adjusting Limit Switches ................ -
Page 46: Adjusting Limit Switches
(amount of movement from the limit switch arm’s resting position to the position at which the switch actuates – with a “click”) is either 5 or 20-degrees. The EP-1 has three 20- degree switches. If the arm is moved to the full extent of its travel and you do not hear the limit switch “click”, the switch needs... -
Page 47: Adjusting The Bolts On The Face Plate Turrets
Check and adjust these two bolts. Repeat until in specification. If only one parameter is out of specification, adjust the bolt linked to that parameter. Repeat until in specification. Adjusting the Vertical Position. FIGURE 4-2. KVAL EP-1 Operation/Service Manual... -
Page 48: 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. The following checks require the electrical panel to be Warning energized. -
Page 49: 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 EP-1 Operation/Service Manual... - Page 50 STEP 6: 24VDC (Green light is OFF go to item on page 4-9. The following checks require the electrical panel to be Warning energized. These troubleshooting checks must be per- formed by a Qualified Electrical Technician. KVAL EP-1 Operation/Service Manual...
- Page 51 If indicator is orange, press the Reset Button to reset the overload circuit. Retest the Machine. Trip Indicator Contactors Test or Stop Factory Set Current Overload Rating Adjust Relays Reset Button. Fac- tory set on the ''H'' Setting. KVAL EP-1 Operation/Service Manual...
- Page 52 Start button and hold it in while a second person checks for voltage between #2 and #5. If there is 110 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wiring. KVAL EP-1 Operation/Service Manual...
- Page 53 Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block. Reinstall the + brown wires one by one checking for +24VDC after installing each + brown wire. If at any point no voltage is found trace the last reinstalled wire and check for shorts. KVAL EP-1 Operation/Service Manual...
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Page 54: Troubleshooting The Air Cylinders
FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS. Check the solenoid air valves: Once activated, The valve will allow full pressure to Caution the cylinder. Make sure you are clear of all moving parts. 4-10 KVAL EP-1 Operation/Service Manual... -
Page 55: Adjusting Cylinder Extension Speed
It might be necessary to call in a specialist or check with KVAL Customer Service at 1- 800-553-5825. If an Air Leak is coming from an exhaust port on the solenoid air bank: a.Check the solenoid for the manual override. - Page 56 Troubleshooting the Air Cylinders 4-12 KVAL EP-1 Operation/Service Manual...
- Page 57 EP-1 start light description router start machine button linear bearing, maintenance schedule power up lock out procedure status light panel Lockout and Tagout Guidelines description use as troubleshooting key stop light description KVAL EP-1 Operation/Service Manual...
- Page 58 1-10 inspect 1-10 KVAL EP-1 Operation/Service Manual...
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