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Kval 979-2 Operation Manual

Miter trim saw system
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Operation Manual
Published: October 14, 2024
Innovation, Quality & Honesty
979-2 Miter Trim Saw System

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Summary of Contents for Kval 979-2

  • Page 1 Operation Manual Published: October 14, 2024 Innovation, Quality & Honesty 979-2 Miter Trim Saw System...

  • Page 2: Proprietary Notice

    . For KVAL Inc authorization to copy this information, please call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call (707) 762-7367. Manual Name...

  • Page 3: Technical Service Support

    Kval Website Learn about Kval, order parts, get information on our array of machines (including new machine releases), learn about our machine software solutions, download machine documentation, view videos of our machines in action, contact all the departments.
  • Page 4 KVAL 979-2 Operation Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction to the 979-2 System...Chapter 1 Overview of the 979-2 ................1-3 About this Manual ..................1-4 Operation Manual ..................1-4 Service Manual ...................1-4 Access Manuals and Videos Easily ..........1-5 QR Code ......................1-5 Safety First! ....................1-6 Safety Sheet Sign-Off Sheet ..............1-6...
  • Page 6 RH Leg Mode ....................2-2 LH Leg Mode ....................2-2 Straight Cut Mode ..................2-2 Powering Steps for the 979-2 .............2-3 Steps Before Powering the 979-2 ............2-3 Powering the 979-2 ..................2-4 Home the 979-2 ..................2-4 Powering Down the 979-2 ................2-5 About Safety Controls ................2-6...
  • Page 7 About Calibrating the LH Leg Mode (0°-45°) ........2-40 About the Modify Presets Screen ............2-41 About Programming the Preset Buttons ..........2-41 Diagnostic Screen ..................2-44 Tour of the 979-2 Machine...Chapter 3 Operator’s Tour ..................3-1 Top View ......................3-1 Operator Controls ..................3-2 About the Operator Interface...
  • Page 8 EtherCAT Box Movable Head ..............3-21 About the Light Tower ................3-22 About the Pneumatic System ..............3-23 About the FRL ...................3-23 About the Valve Banks ................3-24 Pneumatic System Overview ..............3-25 About Sensors ...................3-26 About Photo Sensors ................3-26 About Proximity Sensors .................3-27 979-2 Sensor Locations .................3-28...

  • Page 9: Introduction To The 979-2 System

    This section describes the method to page 1-19 Getting Help from KVAL contact the KVAL service center for help. The section includes how to get informa- tion from the specification plate tor pro- vide to KVAL, service center hours, and...

  • Page 10: Overview Of The

    Overview of the 979-2 is designed to cut casing and/or brickmould for doors and win- Kval model 979-2 Miter Trim Saw dows at a rate of 25 pieces per minute. The blades saw down through the face of the casing to eliminate tear out on the face, like a standard miter saw.

  • Page 11: 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 See “Access Manuals and Videos Easily” on page 1-5. Operation Manual includes the following: Operation 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 below 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: Compressed Air

    Safety Guidelines • Never perform any maintenance unless machine is at zero state. • Never clean the machine while it is running. • Never walk away from the machine while it is running. • Never operate the machine without the safety guards. Machine Safety Labels FIGURE 1-4.
  • Page 16 Safety Guidelines Before performing any repairs or maintenance, lockout and tagout must be installed at all loca- tions. See “Lockout/Tagout Procedure” on page 1-14. All maintenance and repairs to electrical circuitry should only be performed by a qualified electri- cian. Warning: Lever style panels have a lock system that can Lever Style Electrical Panels:...

  • Page 17: Pinch Points

    Safety Guidelines Pinch Points A pinch point is a mechanical point where a person or part of a person's body can be caught between moving parts of a machine, between the moving and stationary parts of a machine, or between product and any part of the machine. Always be aware of the safety stickers on the machine Different versions of the stickers may have been applied to the machine.

  • Page 18: Laser Warnings

    Compliance with Codes and Regulations advises that you request an on-site state safety review of your installation of this machine. Kval This is to ensure conformance to any additional specific safety and health regulations which apply in your geographic area.

  • Page 19: Lockout Tagout Air Supply

    Safety Guidelines Lockout Tagout Air Supply Turn all air valves to the OFF position and place a padlock through the hole (see illustration below). NOTE: Place your tag on the padlock, as per the tagout guidelines. Safety Guidelines 1-12...

  • Page 20: 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 21: 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 22: Lockout/Tagout Air Supply

    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 23: Post Maintenance Steps

    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 24: 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 1-19. 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 25: Close The Cage Gate

    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 1-18...

  • Page 26: 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 27: 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 28: 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 29: 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 31: Operation Of The 979-2

    Summary Page 979-2 Modes Summary of the types of cuts offered by page 2-1 the machine. Powering Operations for the 979-2 Instructions to power up and power down page 2-3 the machine. Descriptions of the types of emergency page 2-6 About Emergency Stops assemblies on the machine.

  • Page 32: About Modes

    About Modes About Modes The four different cut modes are illustrated below. See “Processing a Casing” on page 2-14 information about selecting the dimensions for the cut. Right Head Left Head Movable Fixed Machine FIGURE 2-1. Header Mode In the mode, both ends of the casing are cut at angles.

  • Page 33: Rh Leg Mode

    About Modes RH Leg Mode In the mode, the pivots to to make the cut while the makes a 0° RH Leg Left Head 45° Right Head cut. The casing is designed for the right hand side of the door frame. 45°...

  • Page 34: Powering Steps For The 979-2

    Powering Steps for the 979-2 Powering Steps for the 979-2 This section describes how to power up and power down the 979-2. Learn all safety precautionary controls on the machine. Important: Powering up the system includes: • Applying power to the entire system.

  • Page 35: Powering The

    Powering Steps for the 979-2 Powering the 979-2 See Figure 2-7 and procedure below. Switch the green switch to the position. Control Circuit Push the green button to complete machine circuitry and get the Start Machine machine ready to operate.

  • Page 36: Powering Down The 979-2

    Powering Steps for the 979-2 Home Button Home Button FIGURE 2-8. The 979-2 s now ready for work. Powering Down the 979-2 Switch the green switch to the OFF position. Control Circuit Turn off the supply air. also recommends that you turn the disconnect switch on the electrical cabinet 3.

  • Page 37: About Safety Controls

    Operator Station About the E-Stop System has an unique cable system that can be accessed from any point of the machine. The 979-2 cable surrounds the perimeter and is attached to an module located next to the E-Stop Operator Station.

  • Page 38: To Activate The E-Stop System

    Push the button at the START MACHINE Operator Station. the Machine. See “Home the 979-2” on page 2-4. 3. Home Activate the machine after the E-Stop: 1. Pull out the E-Stop button 2. Push the Start button Typical E-Stop Location FIGURE 2-12.

  • Page 39: Before Processing A Casing

    Step 1: Pre-Process Steps and Home the Machine Ensure factory air is present at the machine and the main air supply valve is 979-2 turned on. Power up the . See “Powering the 979-2” on page 2-4. 979-2 At the screen select the button. Main Control...

  • Page 40: Adjustment Procedures

    Before Processing a Casing Load Parameter Steps FIGURE 2-14. Step 3: Mechanical Setup After the moves into position, adjust the . See Figure 2-15 Movable Head Feed System Assemblies on page 2-9 to identify the adjustments. 45° Clamp Center Rest Length Stop Adjust Outer Brushes Thickness Adjust...
  • Page 41 Before Processing a Casing Length Stop Adjust - Adjust to the length of the casings Adjust Knobs Adjust both to the width of the casings with roughly adding 1/8-inch. Width Stops Fine adjustments can be made at the start of processing the casings. Note: Width Adjust - Width of casing + roughly 1/8''...
  • Page 42 Before Processing a Casing Adjust Lever Width Ruler Reference Before Processing a Casing 2-11...

  • Page 43: Special Adjustments

    Special Adjustments Special Adjustments Other adjustments include adjusting the positions and inserting the Brush Center Rest About the Brushes Each has a set of inner and outer brushes. Carriage Head • The inner brushes are located behind the plexiglass cover. •...

  • Page 44: About The Center Rest

    Special Adjustments above 3/4'' and up to 1.5'' thick, use the upper mounting holes for both the inner and outer brushes. Use the slots in the brackets for fine adjustments. Thicker Mounting Hole greater than 3/4” up to 1.5” Mounting Hole 3/4”...

  • Page 45: Processing A Casing

    Processing a Casing Processing a Casing After following the steps in “Before Processing a Casing” on page 2-8 , the casings can be pro- cessed. Press the to power the machine. The machine is 1. Press the Start Button: Start Button now ready to process casings.
  • Page 46 Processing a Casing Ensure the machine is properly set up for the casings by adjusting 4. Fine Adjustments: the following: • Make sure there is a 1/8” gap on both sides of the machine. If not, adjust the Width: width stops until 1/8” gap is met. 1/8”...
  • Page 47 Processing a Casing After fine adjustments, begin processing the casings by oper- 5. Process the Casings: ating the Foot Pedal. a.Tap the pedal twice. b.Hold the pedal down to start the sequence. After the is activated, 6. Machine in Action: Foot Pedal a.The machine pulls in the casings by way of the Feed Dogs...

  • Page 48: Summary Of The Interface

    Summary of the Interface Summary of the Interface The software includes a single to control the entire machine. The interface uses side User Interface “jump buttons” to navigate the software. Main Screen At the screen: Main • Select the type of cut. •...

  • Page 49: Modify Presets Screen

    Summary of the Interface Manual Screen FIGURE 2-20. Modify Presets Screen At the screen, assign cut parameters to the buttons located at the screen. Modify Presets Main • Label the buttons • Decimal and fractional methods are available. “About the Modify Presets Screen” on page 2-41. Modify Preset Screen FIGURE 2-21.

  • Page 50: Diagnostics Screen

    Summary of the Interface Calibration Screen FIGURE 2-22. Diagnostics Screen At the screen: Diagnostics • View the machine tasks including error codes. • Track daily and total counts. “Diagnostic Screen” on page 2-44. Diagnostic screen FIGURE 2-23. Summary of the Interface 2-19...

  • Page 51: Universal Displays

    Universal Displays Universal Displays displays are located on every screen. The displays include machine feedback, jump Universal to screen buttons, button, and the button. Home Reset Feedback Jump Buttons Feedback Home Machine Reset Machine Displays FIGURE 2-24. About the Jump, Reset, and Home Buttons Home Machine: Jump Buttons: This button starts the home sequence on the...

  • Page 52: Machine Feed Back

    Universal Displays Machine Feed Back At the top and at the bottom right hand corner of all user screens is status feedback information. The information generated is as follows:’ • This field lists the machine status through-out the process. Main Status: •...

  • Page 53: Main Screen

    Main Screen Main Screen screen is also the startup screen for the . At this screen, all the basic user interface Main 979-2 controls are available to run a cut on a casing They include buttons, buttons, and a Mode Preset casings.

  • Page 54: About The Preset Buttons

    Main Screen About the Preset Buttons • The buttons are a link to stored cut parameters per mode. Preset • The buttons jumps to more buttons. Page Preset • The button uploads the selected parameters Download Cut Parameter Preset Button to process the casings.

  • Page 55: About Manual Operation

    About Manual Operation About Manual Operation At this screen, you can control certain functions of the machine manually. This screen is can be used in troubleshooting, checking cut specifications, and maintenance. Select the Manual Mode button to activate all the buttons at the screen. However, the button is always Exit Application active.

  • Page 56: Manual Mode On/Off

    About Manual Operation Manual Mode On/Off To activate all the buttons on this screen, select the button to toggle to the posi- Manual Mode tion. The buttons turn from gray backgrounds to colorful backgrounds. Figure 2-32 shows the screen with activated.

  • Page 57: Movable Head Buttons

    About Manual Operation Click the button from the pop-up window. Start HMI Icon -Double Click Start Button -Click HMI Icon FIGURE 2-34. Movable Head Buttons Press and hold the buttons to open or close the ). At the Movable Head Movable Head Left Head enter the desired speed of the...

  • Page 58: Saw Adjust Buttons

    About Manual Operation Feed Cylinders Adjust Buttons buttons extend or retract the and the casing Feed Cylinder Feed Dog Cylinders 90° 45° clamps. See “About the Feed System” on page 3-8 for a visual of the feed cylinders and casing clamps.

  • Page 59: Burn In Chipout Button

    Burn in Chipout Button Burn in Chipout Button is a powerful electro-mechanical motion con- 979-2 Caution trol system. If servicing the follow the safety 979-2 guidelines. Failure to do so can result in damage to equipment and/or serious injury to personnel.
  • Page 60 Burn in Chipout Button Locate the chipout block and loosen the two set screws located 4. Loosen Set Screws: on the side of the block assembly. Use a 1/8” Allen wrench. Loosen the set screws using a 1/8” Allen wrench. Remove the old chipout block.

  • Page 61: Process To Burn In A Chipout Block

    Process to Burn in a Chipout Block Process to Burn in a Chipout Block After the chipout block has been replaced and the machine has been made safe, burn in the chipout block. To burn in a chipout block, use the and the button in tan- Foot Pedal...

  • Page 62: Process To Remove And Replace The Saw Blade

    Process to Remove and Replace the Saw Blade Process to Remove and Replace the Saw Blade is a powerful electro-mechanical motion con- 979-2 Caution trol system. If servicing the follow the safety guide- 979-2 lines described in. Failure to do so can result in damage to equipment and/or serious injury to personnel.
  • Page 63 Process to Remove and Replace the Saw Blade Close out the popup. Bleed the airline. Perform 2. Lockout/Tagout: Alert Lockout/ Tagout Remove the plexiglass covers to get access to the chipout blocks. 3. Remove Covers: Remove Plexiglass Covers Cut the zip tie that secures the air hoses to the side of the machine. This 4.
  • Page 64 Process to Remove and Replace the Saw Blade Insert the 10 mm Allen wrench into the motor shaft to hold 6. Loosen Saw Hardware: the shaft steady. Place the 36 mm wrench around the holding nut and break the nut connection.
  • Page 65 Process to Remove and Replace the Saw Blade To install the new or sharpened saw blade, the previ- 8. Install the Saw Blade: reverse ous process steps in this procedure. a.Carefully slide the new saw blade onto the shaft. b.Install the washer and nut. Ensure the shoulder or recessed side of the nut is facing the washer.
  • Page 66 Process to Remove and Replace the Saw Blade e. Re-install all guards. f.Make sure that the machine safe. Reverse Lockout/Tagout. Process to Remove and Replace the Saw Blade 2-35...

  • Page 67: About The Calibration Screen

    About the Calibration Screen About the Calibration Screen If slight inaccuracies are discovered in the bevel cuts, select the button to calibrate the Calibration machine. If all mode cuts are out of specification by the same amount, perform the calibration All Bevels otherwise select the mode calibration that is out of specification.

  • Page 68: Measure The Casings

    About the Calibration Screen X-Axis Negative Movement X-Axis Positive Movement Calibration Parameters FIGURE 2-39. Measure the Casings If concerned about the calibration, process a reference of the suspect cut. Measure from the edge of the casing to the beginning of the cut for angle.

  • Page 69: Entering Calibration Data

    About the Calibration Screen Entering Calibration Data Follow the procedure below to calibration the system. See Figure 2-41. If there is a number next to the text, click to combine both num- Base Combine with Base bers. Click the to display the keypad. Enter the positive or negative amount to correct ±...

  • Page 70: About Calibrating All Bevels

    About the Calibration Screen About Calibrating all Bevels If all the casings are out of specifications, select the calibration. calibrates All Bevels All Bevels the entire which affects all modes. Select one of the casing modes and run the Saw Head Carriage calibration routine.

  • Page 71: About Calibrating The Rh Leg Mode (45°-0°)

    About the Calibration Screen About Calibrating the RH Leg Mode (45°-0°) If cuts with the are out of specification, select this calibration. Select RH Leg Mode All Bevels follow the calibration procedure in “Measure the Casings” on page 2-37 “Entering Calibra- tion Data”...

  • Page 72: About The Modify Presets Screen

    About the Modify Presets Screen About the Modify Presets Screen At the screen, program the buttons that are located on the Modify Presets Preset Main Screen • Add a title to preset button. • Add parameter data as a fraction or as a decimal. •...
  • Page 73 About the Modify Presets Screen 1. Select Mode 2. Select Preset Main Screen FIGURE 2-47. At the right-side menu, select Modify Presets 3. Select Modify Presets Modify Presets Button FIGURE 2-48. At the screen: Preset a.Enter a title. b.Enter the a decimal or fractional length. For fractional input, either enter data directly into the text box or Note: use the...
  • Page 74 About the Modify Presets Screen 4 a. Enter Preset Button Title 4 b. Enter Length Parameters -Fractional or Decimal 4 c. Save and Store Data Preset Screen FIGURE 2-49. Select the button to go back to the main menu. The previously selected button Main will have the title and length labeled on the button.

  • Page 75: Diagnostic Screen

    The top line will have the most current routine that is running. If the machine issue cannot be resolved, contact at (1-800-553- Kval Technical Service Support 5825). Have the error code that is displayed, ready to give the representative. This will aid in Kval troubleshooting and shorten down time.

  • Page 77: Tour Of The 979-2 Machine

    CHAPTER 3 Tour of the 979-2 Machine This chapter describes components, assemblies, and the user interface of the 979-2 machine. content is geared to help operators understand the basic operation of the machine. pter 3 at a Glance Section Name...

  • Page 78: Operator's Tour

    In-Feed Staging Area -Hopper -Feed-In -Center Support Feed Out Area Never enter or reach in this area when machine is in operation Start Sequence Movable Head Right/Movable Head Valve Bank Identification of Key Assemblies of 979-2 FIGURE 3-1. Operator’s Tour...

  • Page 79: Operator Controls

    Operator Controls Operator Controls contains a touch screen that allows communication between the operator and Operator Station the machine. Through automation, the station interface replaces manual setup, thereby saving time. Cutting parameters can be stored and retrieved by one touch. Figure 3-2 identifies the controls: Operator Interface...

  • Page 80: About The Operator Interface

    Operator Controls About the Operator Interface eases processing of casings. Touch screen selections allow the operator to Operator Interface quickly change the saw head between 45 degrees and 90 degrees. The distance between the saw blades is controlled with presets for all popular casing and door stop lengths.

  • Page 81: About The Foot Pedal

    Foot Pedal FIGURE 3-4. About the E-Stop System has an unique cable system that can be accessed from any point of the machine. The 979-2 cable surrounds the perimeter and is attached to an module located next to the E-Stop Operator “About Safety Controls”...

  • Page 82: Front Section

    Front Section Front Section At the front section, the operator controls the operation of the machine. See Figure 3-6 for an illustration of key parts of the front section. Feed System Hopper System E-Stop System -Hopper -Adjustable Stops -E-Stop Module -Dog Feed -360°...
  • Page 83 Front Section Finished Product Out-Feed Key Parts FIGURE 3-7. Front Section...

  • Page 84: About The Feed System

    About the Feed System About the Feed System The feed system adjusts to the length of the casings. The casings are then fed-in from the Hopper The feed system assemblies include the following: • Width System • Feed System About the Width System The machine auto-adjusts to the length of the casings by way the servo-driven Movable Carriage .

  • Page 85: About The Feed System

    About the Feed System About the Feed System At the , casings are loaded into a and then manually fed to reciprocating feed Feed System Hopper dog system. TABLE 3-1. Assembly Description Feed Dogs The Feed Dogs are a pneumatically driven and move the casings through saw cutting process.

  • Page 86: Adjustable Feed Assemblies

    About the Feed System Adjustable Feed Assemblies contains adjustable assemblies to adapt to the casings. See Figure 3-10 for iden- Feed System tification of key components of the Adjustment Assemblies. “Mechanical Setup” on page 2-9 for a procedure to set the assemblies. TABLE 3-2.

  • Page 87: About The Saw Cutter Heads

    About the Saw Cutter Heads About the Saw Cutter Heads has a Heads and a . Each head has the same 979-2 Fixed Saw Cutter Movable Saw Cutter Head components. The main components in the are listed in Table 3-3. See Figure 3-11 for an illus- Saw Cutter Head tration of the location of the components.
  • Page 88 About the Saw Cutter Heads Saw Lock Cylinder Extend Shock Absorber Retract Shock Absorber Vertical Cylinder 90° Casing Clamp 45° Casing Clamp Saw Blade Saw Motor Shock Absorber -Feed Extend 45° Saw Plate Assembly Chipout Block Feed Dogs 45° Cylinder Feed Cylinders Shock Absorber -Feed Retract...

  • Page 89: About The Electrical Panel

    If working on the panel, follow disconnect protocol. has a that supply voltage, apply a motors, and control servo 979-2 Main Electrical Panel motors. This section is an overview of the electrical components. Each area identified in Figure is described in the following sections.

  • Page 90: Plc Section

    About the Electrical Panel PLC Section section of the predominately contains components for the on-board Electrical Panel industrial computer. Table 3-4 and Figure 3-13 identify the locations and describe the components of the section. Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.

  • Page 91: How To Use The Vpn

    The VPN is an industrial remote access router that is designed to offer remote access, across the Internet, to the 979-2. Kval technicians can troubleshoot machines, debug the PLC pro- gram while the operator runs the machine. The VPN works in the background.

  • Page 92: Analog Voltage Section

    About the Electrical Panel Analog Voltage Section This section predominately contains components that control, supply, or route the analog volt- ages. Table 3-5 on page 3-15 and Figure 3-13 identify the locations and describe the components of the section. Analog Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion.

  • Page 93: Servo Drive And Vfd Section

    About the Electrical Panel Table 3-6 and Figure 3-16 identify the locations and describe the components of the Input Power section. Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion. Power Disconnect Switch Circuit Breakers Power Input Section FIGURE 3-16.
  • Page 94 About the Electrical Panel Fuses -Servo Drives Circuit Breakers -VFD Heat Exchanger Servo Drive Module Heat Exchanger Servo / VFD Drive Section FIGURE 3-17. Servo Drive Section Descriptions TABLE 3-7. Component Description Circuit Breakers Circuit breakers protect components on the machine when an over-current incident occurs.
  • Page 95 About the Electrical Panel Servo Drive Section Descriptions TABLE 3-7. Component Description Heat Exchanger VFD thermal overload protection is provided by a thermal resistor (Heat Exchanger.) The thermal resistors will sense over current and shut down process or act like a brake to stop the saws quickly during shutdown of the saws.

  • Page 96: Electrical Panel Connections

    About the Electrical Panel Electrical Panel Connections Refer to the machine’s electrical schematics for detailed information. Main E Box: Contains Servo Drives. Network Connections, power, and Inputs/Outputs originate at this box and are connected to Nodes. Location of Nodes on Machine FIGURE 3- 18.

  • Page 97: About Network Topography

    About Network Topography About Network Topography EtherCAT Boxes are located throughout the machine. The boxes have digital inputs to acquire the binary control signals from the process level and transmit them to the . The state of the signals is indicated by light emitting diodes. The signals are connected via M8 screw type connectors. Refer to the electrical schematic for more detailed information Note: .EtherCAT Box Fixed Head...

  • Page 98: Ethercat Box Movable Head

    About Network Topography EtherCAT Box Movable Head The EtherCAT boxes on the side drive processes. Movable Head Movable Head Movable Head Feed Extended Feed Retracted Saw Angle Fixed (0°) Saw Angle Fixed (45°) Saw Extended Saw Retracted Board Straight Movable Head EtherCat Box Movable Head EtherCat Boxes FIGURE 3-20.

  • Page 99: 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 100: About The Pneumatic System

    About the Pneumatic System About the Pneumatic System The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine. The clean dry air is diverted to blow off nozzles. The lubricator, located after the CDA filters, delivers the lubricated air to valve banks and air cylinders.

  • Page 101: About The Valve Banks

    About the Pneumatic System About the Valve Banks Control valves (solenoids) are used to drive cylinders to move different loads in the machine. An EtherCAT interface provides communication to and from the to drive air solenoids. The sole- noids are connected to the top of the manifold. Labels indicating their function and connec- tions are attached to the solenoid body.

  • Page 102: Pneumatic System Overview

    About the Pneumatic System Pneumatic System Overview Figure 3-24 below show the locations and descriptions of the components of the Pneumatic Sys- tem. The air cylinders are paired, located on the Fixed Saw Carriage and the Movable Note: Saw Carriage. The figure below can be considered as an overview of the pneumatic system.

  • Page 103: About Sensors

    Enter the machine serial number or machine model to access docu- port mentation for this machine. https://kvalinc.com/machine-support QR Code to goto Kval Support Page FIGURE 3-25. About Photo Sensors A photo sensor, also known as a photo detector or a light sensor, is a device that detects light or the absence of light and converts it into an electrical signal.

  • Page 104: About Proximity Sensors

    About Sensors About Proximity Sensors Metal sensors detect the presence of metallic assemblies as the machine operates. These sensors help ensure product integrity, prevent damage to equipment, and maintain safety standards by identifying any unexpected metal pieces in the processed items. Figure 3-27 below shows a gen- eral example of types of proximity sensors.

  • Page 105: 979-2 Sensor Locations

    979-2 Sensor Locations 979-2 Sensor Locations sensors are predominately metal sensors with some photo sensors. 979-2 The next figure is designed to be a general sensor location map. For a detailed Note: map, see the Electro-Mechanical Map Homing Sensors In Machine Sensors...
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