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Kval KvalCAM DL-NCX Service Manual

Door machining system
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Innovation, Quality & Honesty
DL-NCX Door Machining System
®
With KvalCAM
Service Manual
Published: February 20, 2024

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Summary of Contents for Kval KvalCAM DL-NCX

  • Page 1 Service Manual Published: February 20, 2024 Innovation, Quality & Honesty DL-NCX Door Machining System ® With KvalCAM...
  • Page 2 Mon-Thu:6:00 AM - 4:00 PM PST Fri: 6:00 AM - 3:30 PM PST Parts Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web- site at the “Contact Us” page. email: parts@kvalinc.com KVAL DL-NCX Service Manual...
  • Page 3 KVAL DL-NCX Service Manual Technical Support For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact Us” page. Mon-Fri:4:00 AM - 4:00 PM PST email: support@kvalinc.com Field Service Support For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the “Contact Us”...
  • Page 4 LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE KvalCAM SOFTWARE. Kval, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are the purchaser of Machinery operated by the KvalCAM Software are the “Licensee”.

  • Page 5: Table Of Contents

    Safety Guidelines..............1-7 Lockout/Tagout Guidelines ............1-8 Lockout/Tagout Procedure............1-9 Zero-Energy to Start-Up ............1-12 Getting Help from Kval............. 1-14 Kval Return and Warranty Policy ..........1-15 Safety Sign-Off Sheet .............. 1-17 Chapter 2 Maintenance of the DL-NCX Maintenance Schedule ............2-1 300 Cycle Maintenance Steps ..........
  • Page 6 Table of Contents How to Access the Tool Config Screen........2-34 Removing the Tool Holder from the Cutter Head..... 2-35 Spindle Care ................2-39 Remove and Replace the Chisels ........... 2-42 Collet Torque Values ..............2-43 Chapter 3 Troubleshooting the DL-NCX Get Live Technical Help ............
  • Page 7 1-12 Zero-Energy to Start-Up time. This section describes the method to contact the page 1-14 Getting Help from Kval service center for help. The section includes Kval how to get information from the specification plate tor provide to , service center hours, and Kval return procedures.

  • Page 8: Overview Of The Dl-Ncx

    Overview of the DL-NCX Overview of the DL-NCX Kval’s Numerically-Controlled Door Light Cut-Out Machine is a robust architectural DL-NCX door processor designed for precision work. It boasts a 15HP spindle, an automatic tool changer, and heavy-duty drives and bearing components. The machine includes an automatic corner squar- ing system for flush glazed light panels, employing a squaring mechanism from Successor Indus- tries.
  • Page 9 Overview of the DL-NCX proprietary Door Software simplifies machinery programming and G-Code creation, KvalCAM enabling easy creation of template files for various hardware cuts (locks, closers, sweeps, hinges, etc.). The software allows one hardware template to accommodate an array of face and edge detailing mortises, integrating multiple machines and tools into a cohesive unit.

  • Page 10: About This Manual

    About this Manual About this Manual This manual is part of a package delivered with the machine line. Manuals and Quick Starts are available on line to download. Videos are avail- Note: able to view. See “Access Manuals and Videos Easily” on page 2-5. Operation Manual includes the following: Operation Manual...
  • Page 11 About this Manual KvalCAM Reference Manual Reference Manual includes the following: KvalCAM Chapter Title Description KvalCAM Reference Description of the Interface. KvalCAM Examples Examples of Common Door Job Features. KvalCAM Common Terms Common terms associated with KvalCAM. About this Manual...

  • Page 12: Access Manuals And Videos Easily

    Access Manuals and Videos Easily Access Manuals and Videos Easily You can easily access a range of resources including downloadable PDF manuals, Quick Start guides, Maintenance Summaries, links to instructional videos, and Electro-Mechanical Maps. To access these valuable materials, simply follow these steps: Visit https://kvalinc.com/machine-support or scan the QR code provided in this sec-...

  • Page 13: Safety First

    Safety Terminology of Labels In addition to the nameplate, machines may have other warning labels or decals that provide Kval safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.

  • Page 14: Safety Guidelines

    Safety Guidelines Safety Guidelines In addition to the caution and warning labels affixed to this machine, follow the guidelines next to help ensure the safety of equipment and personnel. Different versions of the stickers may have been applied to the machine. The Note: intent of safety is the same.

  • Page 15: Lockout/Tagout Guidelines

    Lockout/Tagout Guidelines Lockout/Tagout Guidelines Follow these Lockout/Tagout guidelines, • Place a tag on all padlocks. On the tag, each operator must put their own name and date. (These locks are only to be removed by the person who signs the tag) •...

  • Page 16: Lockout/Tagout Procedure

    Lockout/Tagout Procedure Lockout/Tagout Procedure This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991. Use the following lockout procedure to secure this machine while it is powered down. During a lockout, you disconnect all power and shut off the air supply.
  • Page 17 Lockout/Tagout Procedure push the red tab to pop it out. Place a pad- Disconnect style Electrical Panels: lock through the hole. Place your tag on the padlock, as per the tagout guide- lines next. (see illustration next). Turn Switch to the Insert Lock into hole.
  • Page 18 Lockout/Tagout Procedure Post Maintenance Steps After maintenance is completed, the person performing the work must ensure all tools, spare parts, test equipment, etc., are completely removed and that all guards and safety devices are installed. Before removing the locks and tags, the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re-energized.

  • Page 19: 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 See “Getting Help from Kval” on page 1-14. Kval Technical Support. Check Controls Confirm that all switches are in the “OFF” position. Please be advised that some components of the machine may start automatically when energy is restored.
  • Page 20 Zero-Energy to Start-Up Close the Cage Gate Verify all cage gates are securely closed. Ensure all safety protocols are in effect. Zero-Energy to Start-Up 1-13...

  • Page 21: Getting Help From Kval

    Getting Help from Kval Getting Help from Kval Before you seek help, first try the troubleshooting procedures. Follow the procedures next. If you are unable to resolve the problem: Locate the machine’s Specification Plate and record the serial number, 3 phase volts, electrical print number, and air print number.

  • Page 22: Kval Return And Warranty Policy

    Kval Return and Warranty Policy Kval Return and Warranty Policy goal is to provide customers with high quality products. If, for any reason, you are not com- Kval's pletely satisfied with your purchase, please contact us at: Email: parts@kvalinc.com +1 (800) 553-5825 Phone: •...
  • Page 23 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 24: Safety Sign-Off Sheet

    Name (print):___________________ Signature: __________________ Date:____/____/____ Supervisor/Safety Officer/Trainer Name (print):__________________Signature: __________________ Date:____/____/___ recommends you make a copy of this sheet for new operators. If a copy is Note: Kval needed, contact our at (800) 553-5825 or email at sup- Technical Support port@kvalinc.com.
  • Page 25 Maintenance of the DL-NCX CHAPTER 2 This chapter describes preventative maintenance steps for The content is geared to Kval DL-NCX. guide technicians to keep a regular maintenance schedule for your machine. Keeping your Kval machine maintained is an important piece for successful operation of your door production Kval process.

  • Page 26: Maintenance Schedule

    Maintenance Schedule recommends the following maintenance schedule to ensure that the machine operates prop- Kval erly. Cycles refers to the quantity of processed doors. Cleaning curtails build up of sawdust and grime which causes issues with the operation of the machine. Inspecting, finds issues before they become problems.
  • Page 27 Inspect Inspect all airlines for kinks or rubbing. Lubricate Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 standard hydraulic oil (KVAL PN:SYS-LUBEG). Lubricate Grease ball screw bearings (if applicable). See “Lubrication Schedule” on page 2-20.

  • Page 28: 300 Cycle Maintenance Steps

    300 Cycle Maintenance Steps 300 Cycle Maintenance Steps Follow Lockout Tagout procedures. Clean, Clean, Clean! has an efficient sawdust removal system, however, daily cleaning is good practice. DL-NCX Use pressured air to blow off dust and debris on entire machine. Use a clean rag to clean areas not affected by pressurized air.

  • Page 29: 600 Cycle Maintenance Steps

    600 Cycle Maintenance Steps 600 Cycle Maintenance Steps Follow procedures. Lockout/Tagout Check Air Gauges and Inspect Water Traps Air Pressure Gages. Adjust, if necessary, to the proper PSI located on the label. Adjust only if trained in maintenance Note: Inspect Air Filter Water Traps. Empty trap if necessary Slide locking switch down to unlock twist trap to remove.
  • Page 30 600 Cycle Maintenance Steps Empty Dust Collection Units 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 2- 4.

  • Page 31: 3,000 Cycle Maintenance Steps

    3,000 Cycle Maintenance Steps 3,000 Cycle Maintenance Steps Follow procedures. Lockout/Tagout Inspect Feed Belts For machines with auto-feed. Note: Inspect feed belts for proper tension or damage. Check belts for cuts and nicks. Belts can stretch over time. Check for looseness. A rule of thumb is to pull belt, if belt moves too freely, then replace belt.
  • Page 32 3,000 Cycle Maintenance Steps Inspect Limit Switches Inspect all limit switch arms for tightness or breaks. Inspect the switch for cracks in the body and check that the switch arm actuates (clicking sound) when moved to the extreme. 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.
  • Page 33 3,000 Cycle Maintenance Steps Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 standard hydraulic oil (KVAL PN: SYS-LUBEG). Slide locking switch down twist bowl and remove. Refill bowl. Reverse action when installing trap. Grease Ball Screw Bearings Grease ball screw bearings (if applicable).

  • Page 34: 12,000 Cycle Maintenance Steps

    12,000 Cycle Maintenance Steps 12,000 Cycle Maintenance Steps Follow procedures. Lockout/Tagout Inspect Chains for Proper Tension Inspect chains for proper tension or damage. Check for sagging chains. Chains can stretch over time of use. Check for chain stiffness. Stiff chains do not provide a tight fit over the gears Chain Inspect Air Cylinders Inspect all air cylinders for air leaks.
  • Page 35 12,000 Cycle Maintenance Steps Inspect Hydraulic Lines (If Applicable) Some machines do not have or need a hydraulic pump to operate. Note: Inspect hydraulic lines for loose fittings, leaks, and cracks. Inspect hydraulic lines from the source to the end assembly. Inspect Ball Rail Shafts Inspect ball rail shafts for pitting or abrasions.
  • Page 36 12,000 Cycle Maintenance Steps Example of a Pitted Ball Screw Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts Clean and lubricate all slides and cylinder rods with dry silicone spray. 12,000 Cycle Maintenance Steps 2-11...
  • Page 37 Check contactors for wear. Computer Backup Right Click the Icon at the Taskbar of the screen to display this Pop-Up. Kval Select the Backup menu choice. In the text box enter any notes/ Save the zip file to the location of choice...

  • Page 38: 72,000 Cycle Maintenance Steps

    72,000 Cycle Maintenance Steps 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. •...

  • Page 39: Maintenance No-Goes

    Maintenance NO-GOES Maintenance NO-GOES Do not perform the following. This machine is tuned an calibrated at the factory. If any of these conditions are changed, timing, accuracy, or damage may occur during the machine process. • Do not adjust air above or below factory settings.

  • Page 40: About Bearings

    About Bearings About Bearings This section describes the parts of the machine that require periodic lubrication, and specifies the lubricants. In addition, it explains how to maintain the lubrication systems on the machine. If the bearing is equipped with a grease fitting (Zerk Fitting). The Zerk fitting is basically a valve that opens under pressure to allow lubricant to pass through a channel and be forced into the voids of the bearing.

  • Page 41: About Pillow Block And Rail Bearings

    About Pillow Block and Rail Bearings About Pillow Block and Rail Bearings A pillow block is any mounted bearing where the mounted shaft is in a parallel plane to the mounting surface, and perpendicular to the center line of the mounting holes, as compared to dif- ferent types of flange blocks or flange units.

  • Page 42: About Ball Rail Bearings

    About Ball Rail Bearings About Ball Rail Bearings are linear bearings that are attached to positioning rails. In most cases, the bear- Ball Rail Bearings ings are attached to assemblies to move them in the X,Y, or Z direction. Ball Rail Bearing Ball Rail Bearings FIGURE 2- 3.

  • Page 43: About Tapered Bearings

    About Tapered Bearings About Tapered Bearings Taper bearings are used for moving the axises of heavy loads with stability. The tapered roller bearing in combination with lubricants is extremely durable and is used in applications involving rotating axle and transmission shafts. Bearing durability is such an asset that the bearing blocks often require no main- Note: tenance for the life of the machine.
  • Page 44 About Tapered Bearings Ball Screw Nut is an assembly with recirculating ball bearings that interfaces with the ball Ball Screw Nut screw. The ball screw drive and the ball screw nut create very low friction coefficients resulting in a smooth, accurate, efficient movement. Ball Screw Nut Ball Screw Nut Housing Ball Screw Drive...

  • Page 45: Lubrication Schedule

    Recommended Schedule Recommended Lubrication Type Linear Bearing Pillow Block (Hub) Every 250 Hours of Machine Operation Bearing Dura-Lith Grease (KVAL P/N Flange Block Bearing Lube EP-2) Ball Screw Every 80 Hours of Machine Operation Idler Shafts (Pulley) Monthly Tapered Bearing...
  • Page 46 Lubrication Schedule Kval Lubrication Kit Hydraulic Oil Silicone Spray Grease Gun EP-2 Multi-FAK Grease Extension Adapter Needle Nozzle E Adapter Needle Nozzle Lubrication Kit FIGURE 2- 8. Lubrication Schedule 2-21...

  • Page 47: Machine Lubrication Map

    Machine Lubrication Map Machine Lubrication Map This machine has multiple grease points. Figure 2- 9 shows an overview of all the grease points. The following sections describe the greasing point in detail. Feed Belt System (Blue) Width System (Green) Carriage (Teal) Servo Assemblies (Blue) -Cutter Head Lubrication Map...

  • Page 48: Procedure To Grease The Carriage Head

    Procedure to Grease the Carriage Head Procedure to Grease the Carriage Head This section details the greasing procedure for the bearings. The Carriage Head and Cutter Head includes servo motor assembly bearings. The servo assemblies move the Cutter Head Cutter Head in highly accurate movements.
  • Page 49 Procedure to Grease the Carriage Head Servo Bearing Locations on the Carriage Head The Carriage Head has six rail bearings attached to the bottom to move the head in the X-Axis direction. The is moved by servo motor assemblies. Cutter Head X-Axis Y-Axis Z-Axis...

  • Page 50: Greasing Cutter Head Bearings

    Greasing Cutter Head Bearings Greasing Cutter Head Bearings This section details greasing procedure for the bearings. These bearings help Cutter Head Carriage move the in the Cutter Head Z-Axis Y-Axis For recommended greasing schedule for all assemblies, see “Lubrication Schedule” on page 2-20. For more information about linear bearings, see “About Ball Rail Bearings”...
  • Page 51 Greasing Cutter Head Bearings in the figure nextnext includes an exploded view for easy bear- Note: Cutter Head ing identification Chisel (Z-Axis) QTY-4 Cutter Head (Y-Axis) Spindle (Z-Axis) Cutter Head (Z-Axis) QTY-4 QTY-4 QTY-4 Cutter Head Bearing FIGURE 2- 11. Greasing Cutter Head Bearings 2-26...

  • Page 52: Greasing The Feed System Bearings

    Greasing the Feed System Bearings Greasing the Feed System Bearings This section details greasing procedure for the feed system. The feed system consists of assem- blies that assist in securing, moving, or measuring the door length within the machine. The feed system assemblies include the following: •...
  • Page 53 Greasing the Feed System Bearings Greasing Door Feed Bearings The door feed system brings the door in for processing based on the Door Job. Once KvalCAM processed, the door is then fed out. Sensors, also known as "Eyes," oversee the door while it's within the machine.
  • Page 54 Greasing the Feed System Bearings Greasing Door Width System The width adjust moves the to the width of the door. A single motor drives the Movable Fence movable fence. The movable side sits upon six rail bearings that are attached to the rails. Addi- tionally, there is a hub bearing fastened to the axle.
  • Page 55 Greasing the Feed System Bearings Greasing Dust Collection Bearings A dust collection assembly is located at the of the machine. The assembly will extend to B Side collect any dust after processing and retract when completed. Bearing Location Bearing Total Qty. Bearing Type Schedule Every 250 Hours of...

  • Page 56: About The Self Lubricator Module

    About the Self Lubricator Module About the Self Lubricator Module This machine contains a self lubricating gear assembly to lubricate the Carriage Rails. How the Self Lubricator Works The self-lubricator is electronic and produces nitrogen gas in the well to increase pressure to push the oil out.
  • Page 57 About the Self Lubricator Module Shutdown the machine and follow the procedure, in Chapter 1. Lockout/Tagout If needed, cut the hose included in the kit to match the one on the machine. Attach the 2 hose connectors to the ends of the new hose. On the new lubricator well, set the dip switches.

  • Page 58: Identifying Cutting Tools

    Identifying Cutting Tools This section describes the tool and motor information needed to replace tools. Tool Information for the Cutter Head Tool Information Cutter Head FIGURE 2- 17. Tool Information Tool Most Kval Collet Spindle P/N Shaft Wrench Callout Common Recommended Torque...

  • Page 59: How To Access The Tool Config Screen

    How to Access the Tool Config Screen How to Access the Tool Config Screen This section includes descriptions of the screen. Tool Config contains: Tool Config Screen • Access to tool specifications. • Pop-up menus to enter information about each tool (Specifications, Router or Drill) •...

  • Page 60: Removing The Tool Holder From The Cutter Head

    Removing the Tool Holder from the Cutter Head Removing the Tool Holder from the Cutter Head For normal operations, the tool is changed automatically.The machine is programmed to select the appropriate tool for the door material. However, a tool may also be changed manually, (for exam- ple, to change a dull bit, if there is a mechanical problem with the tool changer, or if you want to replace the tool when the machine is off).
  • Page 61 Removing the Tool Holder from the Cutter Head Changing a Tool Bit and Using Tool-Change Tightening Fixture The section describes how to change the bit in a tool, use the Tool-Change Tightening Fixture, and enter data into the Tool Setup Group. HSK Flange Spindle HSK Tool Holder Option Collet Nut...
  • Page 62 Removing the Tool Holder from the Cutter Head How to Change a Tool Bit Set the tool in the Tool-Change Tightening Fixture. Quick Release will snap into place after collet is inserted into V-Flange: base Flat Edges are Orien- tated in Line with Knob Fully Assembled Tool Tool-Change Fixture Locked in to Place...
  • Page 63 Removing the Tool Holder from the Cutter Head Measure the parameters listed next: • Total Tool Length - The distance from the collet face to the tool’s tip of the pit • Tool Cutting Length - The distance from start of the cutting area to the tip of the bit.

  • Page 64: Spindle Care

    Spindle Care Spindle Care ® The information next is a excerpt from HSD Manual #5801H0056. This excerpt describes the ® care of the tool holder in the spindle shaft. For more information, visit the HSD website at https://www.hsdusa.com. Spindle Care 2-39...
  • Page 65 Spindle Care Spindle Care 2-40...

  • Page 66: Remove And Replace The Chisels

    Remove and Replace the Chisels Remove and Replace the Chisels This machine is a powerful electro-mechani- Warning cal motion control system. If servicing this machine, follow the safety guidelines. Failure to do so can result in damage to equipment and/or serious injury to personnel. Shutdown the machine and follow the Lockout Tagout procedures.

  • Page 67: Collet Torque Values

    Collet Torque Values Collet Torque Values recommends torquing the collets. Torquing adds consistency and is important for repeatable Kval machining. Follow the torque tool manufacturers method of torquing. Recommended Maximum Collet Torque Values Perske Spindle Kval Horse Type Colombo Kval Horse Type...
  • Page 68 FIGURE 2- 23. Addition Collet Torque Values The table next includes additional collet torque values. Collet Torque Values TABLE 2- 4. Collet Nut Type Torque Common Kval Motors SOYUS 20 Hook 36 ft/lbs PERVS503 ER25 Slotted 77 ft /lbs ,HSDY6162Y0071...
  • Page 71 Chapter 3 at a Glance Section Name Summary Page Get live help from Kval Technical Support. Sup- page 3-1 Get Live Help port Technicians can log on the machine and help troubleshoot. A description of the Light Tower and general trou-...

  • Page 72: Get Live Technical Help

    • Access to a broadband internet connection • A computer running Windows • Our remote support client Allow to logon to the machine Kval Exit the ® program. On the Windows screen, select the KVAL Service Icon KvalCAM Get Live Technical Help...

  • Page 73: About The Light Tower

    About the Light Tower About the Light Tower indicates the working status of the system. Highly visible indicator lights are Light Tower mounted on top of the Electrical Boxes. A series of colors and flashing codes helps determine the machine error. In this section, troubleshooting steps are defined.

  • Page 74: Safety And Reference Information

    Safety and Reference Information Safety and Reference Information Follow procedures before troubleshooting. See the Safety Lockout/Tagout chapter in your for steps to lockout your Operation or Service Manual machine. The following checks may require the electrical panel to be opened. High Voltage is present.
  • Page 75 Safety and Reference Information Description of the Light Icons in this Section In this section, icons are used to described the light status. The illustration next describes meaning of the icons. The icons are colored coded within the following sections. Note: ON-Solid ON-Flashing...

  • Page 76: Normal Light Sequence

    Normal Light Sequence Normal Light Sequence The normal sequence of the light tower operation is as follows. See Figure 3-26 next. Light Location Color Icon Summary Solid If the bottom light is solid green, the control power circuit Bottom Green is valid.
  • Page 77 Normal Light Sequence Error Messages If errors occur, check the monitor for error messages and then follow the displayed instructions. Check the interface for the error messages. Combining the messages and status light condition can help find the area to troubleshoot. Troubleshooting High Voltage may cause injury or death.

  • Page 78: Bottom Light (Control Power)

    Bottom Light (Control Power) Bottom Light (Control Power) Control status reflects the condition of 24 VDC control and the circuit associated with it. Figure 3-27 shows the bottom light configuration. Common troubleshooting practices are described in the following section. Bottom Light Conditions The bottom light is either Location Status...
  • Page 79 Bottom Light (Control Power) If the Bottom Light is ON If the bottom light is green and , it confirms that the 24VDC control power circuit is operational. Next, the system check will continue to the middle light (Safety.) Bottom Light (Control Power)

  • Page 80: Middle Light (Safety Power)

    Middle Light (Safety Power) Middle Light (Safety Power) The middle light reflects the condition of internal and external safety assemblies. Figure 3-28 shows the light configurations and the following sections describe common troubleshooting prac- tices. Middle Light Conditions The middle light has three color conditions: Location Color Link...
  • Page 81 If the light is off, check all the yellow safety modules . The LEDs should be solid. If the LEDs are blinking, there is an issue. Once the module is identified, contact Kval Technical Support and they will hook up on line with you and help troubleshoot the issue.
  • Page 82 This can be an internal error with the safety portion of the PLC or an external error with the safety system. • If you checked everything and everything looks good, you may need to call Kval Technical Support and they will hook up on line with you and help troubleshoot the issue.
  • Page 83 Middle Light (Safety Power) If the Middle Light is Green After the is pushed, the light turns to a solid green. Start Button Reset Button This indicates, the safety sensors are good. Next, the Machine Status (Top Light) light sequence will begin. Middle Light (Safety Power) 3-12...

  • Page 84: Top Light (Machine Status)

    Top Light (Machine Status) Top Light (Machine Status) The Machine Status light reflects the condition of internal assemblies, external influences, and triggers operator interaction. Figure 3-29 shows the light configurations and the next section describes common troubleshooting practices. Top Light Conditions The top Machine Status Light has five color conditions.
  • Page 85 Check all I/O modules to make sure the signals are getting back to the PLC. 2. If this can’t be determined, call Kval Technical Support for assistance. They will need to hook up on line and verify that all components are in the OP state.
  • Page 86 There may be an OP error. If no error codes pop up, call Kval Technical Support for assistance. They will need to hook up on- line and verify that all components are in the OP state.
  • Page 87 Top Light (Machine Status) If the Machine Status Light is Yellow If the top light is yellow, an external error is possible. There are three condi- tions for the yellow light. See the table next. Condition Description Yellow Solid Solid yellow indicates a general error. Note: For example, a general error could be a malfunctioning dust collec- tion unit.
  • Page 88 Top Light (Machine Status) Condition Description Blue Solid Solid Blue indicates that the machine is waiting for the operator to do something. • Look at the operator interface for instruction. Note: Generally, this task is to clamp a jamb, re- home the machine, or re-clamp the door.
  • Page 92 http://www.kvalinc.com...

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