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Kval 990-F4 Service Manual

Door pre-hanging system
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Service Manual
Published: November 12, 2021
Innovation, Quality & Honesty
990-F4 Door Pre-Hanging System

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  • Page 1 Service Manual Published: November 12, 2021 Innovation, Quality & Honesty 990-F4 Door Pre-Hanging System...
  • Page 2 6:30 AM to 1:30 PM Pacific Standard Time, Friday Parts & Service Sales: 6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday 6:30 AM to 1:30 PM Pacific Standard Time, Friday (Other sales related inquiries: http://www.kvalinc.com) • Email: service@kvalinc.com KVAL 990-F4 Service Manual...
  • Page 3 KVAL 990-F 4 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-F4 Service Manual...

  • Page 5: Table Of Contents

    Table of Contents Chapter 1 at a Glance.............. 1-1 Overview of the 990-F4 ............1-2 Options Available ..................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 Lockout Tagout Procedure............
  • Page 6 Maintenance NO-GOES ............3-16 Lubrication Schedule ............... 3-17 Typical Lucubration Kit................3-17 Lubrication Requirements............3-18 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 ..................3-21 990-F4...
  • Page 7 Air Input with Lubrication ..............3-31 Air Line Without Lubricator ..............3-32 Replacing Tooling in the Front Section ........3-33 Tool Locations in the 990-F4 Carriage Head ........3-33 How to Access to Bit Assemblies............3-34 Remove and Replace the Router or Pre-Drill Bits (Point to Point) ..3-34 Remove and Replace Pre-Drill Bits (Block) ........3-36...
  • Page 8 Troubleshooting the Air Cylinders ..........4-23 Adjusting Cylinder Extension Speed:..........4-24 Adjusting Cylinder Retraction Speed: ..........4-24 Troubleshooting Electrical Problems ........4-25 If the Power Stops During Normal Operation ........4-25 Troubleshooting with the Status Light Panel ........4-26 Symptoms and Possible Causes ..........4-30 990-F4...

  • Page 9: Chapter 1 At A Glance

    Procedure to power up your machine for the first time. page 1-13 Zero-Energy to Start-Up This section describes the method to contact the KVAL page 1-15 Getting Help from KVAL service center for help. The section includes how to get...

  • Page 10: Overview Of The 990-F4

    Overview of the 990-F4 Overview of the 990-F4 is designed for both interior and exterior 990-F4 doors and jambs. It will accommodate 1-3/8" and 1-3/ 4" doors with a minimum width of 18" and a maximum width of 48" and door lengths of 6' 8" or 8' 0". The machining sequence includes automatic routing of either 3-1/2"...

  • Page 11: Options Available

    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 990-F4 is being machined as a right hand door and off for a left hand door.
  • Page 12 Overview of the 990-F4 Option Title Description Option K Eight-Shooter Screw Gun for 4" X To attach 4" X 4" hinges to the door and jamb, No. 10 by 3/4" long flat 4" Hinge head screws are automatically sorted and fed, eight (8) at a time, to the screw gun.

  • Page 13: About This Manual

    Overview of the 990-F4 About this Manual This manual is part of a package delivered with the machine line. Integration Package includes the following: includes the following: Operation Manual Chapter Title Description Introduction Descriptions of Machine Line and Safety Information.

  • Page 14: Safety First

    Training Ensure that all employees who operate this machine are aware of and adhere to all safety precautions posted on the machine and are trained to operate this machine in a safe manner. KVAL 990-F4 Service Manual...
  • 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 1-11. KVAL 990-F4 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-F4 Service Manual...
  • Page 17 Follow Your Company’s Safety Procedures In addition to these safety guidelines. Your company should have on-site and machine specific safety proce- dures to follow. KVAL 990-F4 Service Manual...

  • 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-F4 Service Manual 1-10...

  • 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-F4 Service Manual 1-11...

  • 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-F4 Service Manual 1-12...

  • Page 21: Zero-Energy To Start-Up

    The Company’s procedures should also include provisions for safely handling shift changes and changes in operators or new operators.Comprehensive lockout/tagout may use a gang box or other system to ensure that locks are secure and not removed without authorization. KVAL 990-F4 Service Manual 1-13...
  • 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-F4 Service Manual 1-14...

  • Page 23: Getting Help From Kval

    • Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485 • Email address is service@KVALinc.com • Hours: 6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday 6:30 AM to 1:30 PM Pacific Standard Time, Friday KVAL 990-F4 Service Manual 1-15...

  • Page 24: Kval Return And Warranty Policy

    KVAL Return and Warranty Policy KVAL Return and Warranty Policy 's goal is to provide customers with high quality products. If, for any reason, you are not KVAL completely satisfied with your purchase, please contact us at: Email: parts@kvalinc.com +1 (800) 553-5825 Phone: •...

  • Page 25: Customer Errors

    KVAL Return and Warranty Policy Customer Errors If the item is to be returned due to customer ordering error, the customer must return the item to or the shipper of origin at its expense. A 15% restocking fee may apply to manufactured...

  • Page 26: How To Download The Service Application

    Explorer and Google web browsers. Sample of Google Browser: Located at the bottom left of the screen. Sample of i.e Explorer: Located at the bottom of the screen. select the arrow and choose Save and Run KVAL 990-F4 Service Manual 1-18...
  • Page 27 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 28 How to Download the Service Application Page Intentionally Left Blank KVAL 990-F4 Service Manual 1-20...

  • Page 29: 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 30 Safety Sign-Off Sheet KVAL 990-F4 Service Manual 1-22...

  • Page 31: About The Plc

    With the controller, KVAL remotely help troubleshoot your machine. Chapter 2 at a Glance Section Name Summary Page This chapter describes the basic parts of the operation of page 2-2 About the PLC the PLC in the machine. KVAL 990-F4 Service Manual...
  • Page 32 This chapter describes the basic parts of the operation of page 2-3 System IT Administration the PLC in the machine. Such as • About the PLC • Connections on the PLC • Backing up the Computer • About Remote Connection to KVAL Service KVAL 990-F4 Service Manual...

  • Page 33: About The 990-F4 Computer

    Connection to the Intranet is achieved by interfacing with the con- 990-F4 troller. The location of the Intranet connection is identified in the figure below (RJ45 to Intranet.) About the 990-F4 Computer ® uses a Beckhoff CPU module as a PLC (Programmable Logic Controller.) In addi- 990-F4 tion to the CPU and the chipset, the module also contains internal main memory.

  • Page 34: Backing Up The Computer

    If any questions occur, contact our service team KVAL at (800) 553-5825 or at www.kvalinc.com. About Remote Connection to KVAL Service Remote access is a powerful tool to help fix issues that occur with the machine. With the...
  • Page 35 • Ball Screws • Description of Air Input System • Adjusting the Air Line Lubricator • Priming the Air Line Lubricator This section describes the methods to replace bits on the page 3-33 Replacing Bits machine. KVAL 990-F4 Service Manual...

  • Page 36: Maintenance Schedule

    Inspect Air Filter Water Traps. Empty if necessary Inspect Inspect the Tooling for wear, (Drill Bits, Cutting Tools, Screw Driver Bits) Inspect Lubricate the inside of the Hoppers with a light coat of dry silicone spry. Lubricate Empty All Dust Collection Units Clean KVAL 990-F4 Service Manual...
  • Page 37 Inspect all airlines for kinks or rubbing. Inspect Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 stan- Lubricate dard hydraulic oil (KVAL PN:SYS-LUBEG). Grease ball screw bearings (if applicable). Lubricate Clean all bearing shafts with clean, dry cloth.

  • Page 38: 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 990-F4 Service Manual...

  • Page 39: 600 Cycle Maintenance Steps

    Inspect Tooling Inspect the Tooling for wear, (Drill Bits, Cutting Tools, Screw Driver Bits) See “Replacing Tooling in the Front Section” on page 3-33 and see “Replacing Tooling in the Back Section” on page 3-40 KVAL 990-F4 Service Manual...

  • Page 40: 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. KVAL 990-F4 Service Manual...

  • Page 41: 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-F4 Service Manual...

  • Page 42: 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-F4 Service Manual...

  • Page 43: 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 44: Grease Ball Screw Bearings

    For locations to lubricate, see “Description of Air Input System” on page 3-31 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-F4 Service Manual 3-10...

  • Page 45: 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-F4 Service Manual 3-11...

  • Page 46: 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 990-F4 Service Manual 3-12...

  • Page 47: 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 990-F4 Service Manual 3-13...

  • Page 48: Tool Changing Schedule

    2,500 cycles 2-1/8” Face Bore Bit 2,500 cycles 2-1/8” Face Bore Bit Inserts 2,500 cycles Insert Scoring Spur for 2-1/8” Bit 2,500 cycles Face Bore Chip-Out Block 2,500 cycles 1” Bolt Drill Bit 2,500 cycles KVAL 990-F4 Service Manual 3-14...
  • Page 49 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 990-F4 Service Manual 3-15...

  • Page 50: 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-F4 Service Manual 3-16...

  • Page 51: Lubrication Schedule

    Assembly Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation Idler Shaft Dura-Lith Grease (KVAL P/N Lube EP-2) Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Tapered Bearing Once 4 X a Year...

  • Page 52: 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 3-1. KVAL 990-F4 Service Manual 3-18...

  • Page 53: 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 3-3. KVAL 990-F4 Service Manual 3-19...

  • Page 54: 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 Bearing Seals Tapered Bearing Housing FIGURE 3-5. KVAL 990-F4 Service Manual 3-20...

  • Page 55: 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 Once 4 X a Year Ball Screw Drive Assembly FIGURE 3-7. KVAL 990-F4 Service Manual 3-21...

  • Page 56: Pulley And Idler Shafts

    Breakout of Pulley Assembly Pulley in Action Grease IN Note: It is important not to overfill the Idler Shaft. Avoid get- ting excess grease on the belts Grease Out Idler Shaft Pulley : Exploded View FIGURE 4. KVAL 990-F4 Service Manual 3-22...

  • Page 57: Sample Of Grease Locations For The Back Section

    Lockout/Tagout before maintenance. For rec- ommended greasing schedule, see “Lubrication Schedule” on page 3-17 Pillow Block (Hub Style Tapered Bearing Housing Ball Screw Nut Servo Motor Back View of 990-F4 Servo Motor Assembly FIGURE 3-1. KVAL 990-F4 Service Manual 3-23...

  • Page 58: Back Section Carriage

    For rec- ommended greasing schedule, see “Lubrication Schedule” on page 3-17 Zerk fitting may be located on th bottom of the bearing. Closed Pillow Block: Quantity = 12 Back View Carriage of 990-F4 FIGURE 3-2. KVAL 990-F4 Service Manual 3-24...

  • Page 59: Sample Of Grease Locations For The Front Section

    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 To get access to the bearings the Hinge Covers will have to be removed. Front View Carriage Head FIGURE 3-3. KVAL 990-F4 Service Manual 3-25...

  • Page 60: Carriage Head Bearings

    Carriage Head X Axis: Moves the head in the Horizontal Axis directions 2 rails 2 bearings per rail Carriage Head Y Axis: Moves the head in the Vertical Axis directions 2 rails 2 bearings per rail Carriage Bearings FIGURE 4. KVAL 990-F4 Service Manual 3-26...

  • Page 61: Tool Bearings

    2 rails 2 bearings per rail 2 rails 2 bearings per rail Tool Box X Axis: Moves the tool box in the horizontal Axis directions 2 rails 2 bearings per rail Tool Set Bearings FIGURE 5. KVAL 990-F4 Service Manual 3-27...

  • Page 62: Front Section Assemblies

    For rec- ommended greasing schedule, see “Lubrication Schedule” on page 3-17 Look under the assembly for the 4. Hub: Hub: Located under assembly Quantity = 1 Quantity = 4 Back of Front Section 990-F4 FIGURE 3-1. KVAL 990-F4 Service Manual 3-28...

  • Page 63: Frame Grease Points

    “Pulley and Idler Shafts” on page 3-22 Hub Bearings 1. Back Frame 2. Back Section 3. Front Section Lubricate Pulleys Lubricate feed system hex shaft with Silicon Spray Top View of 990-F4 FIGURE 3-2. KVAL 990-F4 Service Manual 3-29...

  • Page 64: Sample Of Grease Locations For Ball Catch Option

    Hand) assemblies on the machine. 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 Ball Catch Bearings FIGURE 4. Rail Bearing: Horizontal movement. Quantity = 4 Rail Bearing: Vertical movement. Quantity = 4 KVAL 990-F4 Service Manual 3-30...

  • Page 65: Description Of Air Input System

    Once you have a steady flow, tighten knob back down until you have one drop per every other cycle. Drop will form at end of cane shaped tube visible inside glass. KVAL 990-F4 Service Manual 3-31...

  • Page 66: Air Line Without Lubricator

    The air input system takes in shop air and supplies clean dry air (CDA). Shop Clean Dry Air (CDA) to Air Blow Off Input Air On- Off Knob Muffler Air Distribution Block Pressure Gauge with adjust Filter (purge) Air Filter without Lubricators FIGURE 3-2. KVAL 990-F4 Service Manual 3-32...

  • Page 67: Replacing Tooling In The Front Section

    Failure to do so can result in damage to equipment and/or serious injury to person- nel. Tool Locations in the 990-F4 Carriage Head This section describes the steps to change the tooling in the Carriage Heads and the Six Shooter Figure 4 below...

  • Page 68: 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. KVAL 990-F4 Service Manual 3-34...
  • Page 69 Values” on page 3-47 Drill Depth Router Depth Set to 2.0” Set to 1 3/4 “ 1 3/4 ““ 2.0 “ Bit Depth Gauge (PN432C) Setting the Bit Depths FIGURE 7. Tighten the collet assembly. KVAL 990-F4 Service Manual 3-35...

  • Page 70: Remove And Replace Pre-Drill Bits (Block)

    Figure below) Tighten the chuck with the chuck key. Inspect and verify the work. Clean the work area. If maintenance is completed, replace dust cover and tighten bolts. Tool 12-00-ZA. Sets length of Pre-drill Bit KVAL 990-F4 Service Manual 3-36...

  • Page 71: Remove And Replace The Screwdriver Bits

    Disconnect air from Six-Shooter using the air-connect slide valves. Slowly slide the valves back toward you; listen for air to be released. Disconnect Air Connect to Bleed- Off Air Disconnect Air FIGURE 8. Push the Six-Shooter assembly toward the machine-it will move slightly. KVAL 990-F4 Service Manual 3-37...
  • Page 72 Remove and Replace the Screw Driver Bits To remove screwdriver bit, push the bit holder (see images) back toward the Six- Shooter assembly and hold: pull bit out of holder Location of Driver Bits Bit Holder Hinge Applicator Gear Box KVAL 990-F4 Service Manual 3-38...
  • Page 73 Shooter assembly and hold while inserting new bit. 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 990-F4 Service Manual 3-39...

  • Page 74: Replacing Tooling In The Back Section

    Lock Bore Motor and Drill: Chip Out Location catch on top edges for Drills locks holes on the face Face Plate a LH or RH door of the door Motor and Drill: Routs face plate. KVAL 990-F4 Service Manual 3-40...

  • Page 75: Changing The Bore Drill

    Note: Make sure the arbor is not bottomed out in the back of the motor. If it is, the arbor will not tighten and will damage the collet or other machine parts. Note: The figure shows the cover off for training purposes. KVAL 990-F4 Service Manual 3-41...

  • Page 76: Changing The Bolt Drill

    Changing the Face Plate Router See “Remove and Replace the Router or Pre-Drill Bits (Point to Point)” on page 3-34 . The motor and bits are the same configuration. KVAL 990-F4 Service Manual 3-42...

  • Page 77: How To Replace The Back Section Chipout Block

    Location (X4) Plates(X2) Hinge Carriage and all functions of the Lock except the Lock Bore. Burn the Chipout. Push the Burn Chipout Button at the Interface. Run a test door to verify a clean cut. KVAL 990-F4 Service Manual 3-43...

  • Page 78: How To Replace The Front Section Chipout Block

    Chipout Block (No Spacer). Perform procedure. • 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-F4 Service Manual 3-44...

  • Page 79: Assembly/Tools

    6 flats of the bolt. See the figure below 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-F4 Service Manual 3-45...
  • Page 80 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-F4 Service Manual 3-46...

  • Page 81: Collet Torque Values

    Collet Torque Values Collet Torque Values recommends torquing the collets. Torquing adds consistency is important for repeatable KVAL machining. Follow the torque tool manufacturers method of torquing. KVAL 990-F4 Service Manual 3-47...
  • Page 82 Collet Torque Values KVAL 990-F4 Service Manual 3-48...
  • Page 83 Includes voltages in the electrical panels, using the Status Light panel page 4-25 Troubleshooting to troubleshoot, and VFD troubleshooting. Electrical Problems A table that lists some common solutions to issues that may occur page 4-30 Symptoms and Possible Causes KVAL 990-F4 Service Manual...

  • Page 84: About Motion Control

    Basic Control Circuit This section describes a basic control circuit. The Figure below shows a block diagram of a com- mon control circuit. There are four parts to a motion control system: KVAL 990-F4 Service Manual...
  • Page 85 • 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-F4 Service Manual...

  • Page 86: Typical Positioning Systems

    Line Voltage here Fuse(s) Output Should measure Relay Line Voltage here Power Input Control Contactor (Coil) Input 120 VAC Power Output DC - Should measure Control Circuit Line Voltage here Common Motor Typical Contactor Control FIGURE 11. KVAL 990-F4 Service Manual...
  • Page 87 Typical Motor Control FIGURE 12. Typical Positioning System Pneumatic Circuit A control valve (solenoid) is used to drive cylinders to move different loads in the machine. For Example: extending and retracting router, drill, clamping a door. KVAL 990-F4 Service Manual...
  • Page 88 24 VDC here 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 Typical Pneumatic Circuit FIGURE 13. KVAL 990-F4 Service Manual...

  • Page 89: 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 990-F4 Service Manual...

  • Page 90: 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-F4 Service Manual...
  • Page 91 • 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 990-F4 Service Manual...

  • Page 92: About A Typical Contactor Control

    Control Circuit Common DC - Control Coil for Thermal 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- 1. KVAL 990-F4 Service Manual 4-10...

  • Page 93: 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 990-F4 Service Manual 4-11...

  • Page 94: About Typical Vfd Motor Drive Control

    Motor should be ON Drive Power Output SD (COMMON) Displays the Motor Frequency 15 to 300 Mhz Control Circuit Common Motor Schematic Drawing of VFD Block Diagram of a Common Drive Control FIGURE 4- 3. KVAL 990-F4 Service Manual 4-12...

  • Page 95: About The Vfd

    Includes: • Control input signals • Speed Functions • Relay Outputs • Jumpers • Output to reset switch Line Voltage IN Converted Signal OUT to Motor Sample of VFD FIGURE 4- 4. KVAL 990-F4 Service Manual 4-13...

  • Page 96: 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 990-F4 Service Manual 4-14...

  • Page 97: 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- 6. KVAL 990-F4 Service Manual 4-15...

  • Page 98: Typical Pneumatic Assembly

    Indicator: a Lit LED indicates the solenoid is in use.Red LED= the ‘A’ Port on a single valve. If double valve, Red LED= the ‘A’ Port and Green LED = the ‘B’ port. Solenoids in Manifold FIGURE 4- 8. KVAL 990-F4 Service Manual 4-16...

  • Page 99: 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-F4 Service Manual 4-17...
  • Page 100 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-F4 Service Manual 4-18...

  • Page 101: 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-F4 Service Manual 4-19...

  • Page 102: 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-F4 Service Manual 4-20...

  • Page 103: About The Machine Sensors

    Door In Limit Machine Eye Back Section Head #3 X-Axis For- ward Limit Head #4 Before Out- Feed Stop Eye Open Width Adjust Safety (Limit Switch) Shooter Close Width After Out-Feed Adjust Safety Stop Eye KVAL 990-F4 Service Manual 4-21...

  • Page 104: Using Sensors To Trouble Shoot

    • Check output voltages of the sensors in the active mode. The voltage should effec- tively equal 0 VDC • Check the output voltages of the sensors in inactive mode.The voltage should effec- tively equal 24 VDC KVAL 990-F4 Service Manual 4-22...

  • Page 105: Troubleshooting The Air Cylinders

    Check the flow controls to see that they are adjusted correctly and to the proper specifications. Check for any obstructions to the cylinders such as Manual over- screws or a misplaced tool etc. FOLLOW ALL ride button SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS. Check the solenoid air valves: KVAL 990-F4 Service Manual 4-23...

  • Page 106: Adjusting Cylinder Extension Speed

    When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty. Adjusting Cylinder Extension Speed: Adjusting Cylinder Retraction Speed: KVAL 990-F4 Service Manual 4-24...

  • Page 107: Troubleshooting Electrical Problems

    SEQUENCE,. If one is tripped there will be a slight resistance to touch and a “click” sound as it is reset. If overload is tripped, the 6 lights will only have control power Check for Tripped Circuits Remove lock and tag outs on the main power sources. KVAL 990-F4 Service Manual 4-25...

  • Page 108: Troubleshooting With The Status Light Panel

    STEP 4: Stop (Amber) If light is OFF go to item page 4-28. STEP 5: Start (Amber) If light is OFF go to item page 4-28. STEP 6: 24VDC (Greening light is OFF go to item page 4-29. KVAL 990-F4 Service Manual 4-26...
  • Page 109 X1 and X2. If no power is measured it is a bad transformer. b.If there is power at X1 and X2, check the other side of the fuse. If now power, replace the fuse. KVAL 990-F4 Service Manual 4-27...
  • Page 110 #2 and #5. If there is 120 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wiring or the contact on the button. Start KVAL 990-F4 Service Manual 4-28...
  • Page 111 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-F4 Service Manual 4-29...

  • Page 112: Symptoms And Possible Causes

    Replace Eye Defective Photo Eye Adjust Feed Belt Height Feed Belt Too Low Door Slams Against Door Feed System Moving To Fast Slow Down DC Drive (call KVAL Stops TECH). Defective Photo Eyes Replace Eye Slide valve on screw drop cylinder...
  • Page 113 Screws Empty Hopper Put Screws in the Hopper Jammed Split Shells Disassemble the Screw Receiver Routers Not Moving Into Through Beams Not Lined Up Pick Up on the Last Router Carriage Home Position to realign. KVAL 990-F4 Service Manual 4-31...
  • Page 114 Symptoms and Possible Causes KVAL 990-F4 Service Manual 4-32...
  • Page 115 Safety Sign Off Sheet Safety Concerns 1-21 screwdriver bits flange block bearing, maintenance schedule 3-17 remove and replace 3-37 sensors troubleshooing 4-22 gear box, maintenance schedule 3-17 types 4-21 service KVAL 990-F4 Service Manual...
  • Page 116 KVAL Service start light description 4-28 status light panel description 4-26 use as troubleshooting key 4-26 tagout procedure 1-11 tapered bearings,lubrication schedule 3-17 troubleshooting using status lights 4-26 TwinCAT 2® software automation software USB module Windows CE® operating system,about...
  • Page 118 Customer Service Contacting KVAL 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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