Subscribe to Our Youtube Channel
Related Manuals for Kval DW-R
Summary of Contents for Kval DW-R
- Page 1 Operation Manual Published: March 10, 2025 Innovation, Quality & Honesty DW-R Rotate Table...
-
Page 2: Proprietary Notice
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 DW-R Operation/Service Manual... -
Page 3: Technical Support
KVAL DW-R Operation/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: Table Of Contents
Table of Contents Chapter 1 Introduction to the DW-R Overview of the DW-R ............. 1-1 About this Manual ..............1-2 Operation Manual .................1-2 Service Manual ..................1-2 Access Manuals and Videos Easily ......... 1-3 QR Code....................1-3 Safety First!................1-4 Safety Sheet Sign-Off Sheet..............1-4 Safety Terminology of Labels..............1-4... - Page 5 Safety Sign-Off Sheet .............. 1-19 A Note to the Operator ..............1-19 Chapter 2 Operation of the DW-R Sequence of Events of the DW-R..........2-1 Powering for the DW-R............2-2 Steps Before Powering the DW-R ............2-2 Powering the DW-R ................2-3 How to Power Down ................2-3 About Emergency Shutdown and Recovery ......
- Page 6 Description of the Six Light Panel ........... 3-10 About the Pneumatic System ..........3-11 About the FRL..................3-11 About the Valve Banks................3-12 Pneumatic System Overview........... 3-13 About DW-R Sensors .............. 3-14 About Photo Sensors................3-14 About Proximity Sensors ..............3-15 About Limit Switches ................3-15 Sensor Locations ..............3-16...
- Page 7 Introduction to the DW-R CHAPTER 1 This chapter provides an overview of the and important Kval DW-R Door Feed and Rotate System safety information to follow when operating the machine. TABLE 1-1. Section Name Summary Page This section provides an overview of the...
-
Page 8: Overview Of The Dw-R
Overview of the DW-R Overview of the DW-R The Powered Auto Rotate Station will be equipped with controls to automatically rotate all doors to be machined as left hand doors, and the capability to rotate every other door to the left hand door position for the machining and assembly of double door units. -
Page 9: About This Manual
See "Access Manuals and Videos Easily"on the next page. Operation Manual includes the following: Operation Manual Chapter Title Description DW-R Introduction Descriptions of Machine Line and Safety Information. Operation Interface Descriptions of how to power machine line, and operator interface user screens. Tour Locations and descriptions of key assemblies on the Machine. -
Page 10: 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 11: 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 12: 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 13: Compressed Air
Safety Guidelines • Never reach into the router area to retrieve a hinge. The router may still be running down after shut down. • Never perform any maintenance unless machine is at zero state. • Never clean the machine while it is running. •... - Page 14 Safety Guidelines Electrical Box Labels FIGURE 1-5. Before performing any repairs or maintenance, lockout and tagout must be installed at all loca- tions. See “Lockout/Tagout Procedure” on page 1-11. All maintenance and repairs to electrical circuitry should only be performed by a qualified electri- cian.
-
Page 15: 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 16: 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 17: 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 18: Lockout/Tagout Procedure
Lockout/Tagout Procedure Lockout/Tagout Procedure This policy is required by OSHA regulation DW-R9DW-R0.DW-R47 and Cal OSHA’S SBDW- R98 ruling of July DW-R99DW-R. 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 19: 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 20: 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 21: Zero-Energy To Start-Up
Replace Guards Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the See “Getting Help from Kval” on page 1-16. 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 22: 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 1-15... -
Page 23: 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 24: 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 +DW-R (800) 553-5825 Phone: •... -
Page 25: Customer Errors
Within 30 days of discovery of Kval said defect, please notify , but no more than one (DW-R) year after delivery will the product Kval be covered under Warranty. The repair, replacement, or payment in the manner described previ- ously shall be the exclusive remedy of Buyer for breach of ’s warranty or for claims based... -
Page 26: 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 27: Chapter 2 At A Glance
Chapter 2 at a Glance Section Name Summary Page Machine Sequence Describes the path of a door in the DW-R. page 2-1 Powering Operations for the DW-R Instructions to power up and power down page 2-2 the machine. -
Page 28: Sequence Of Events Of The Dw-R
Sequence of Events of the DW-R Sequence of Events of the DW-R is equipped with software controls to automatically rotate doors to be machined as left DW-R hand doors. The software selections can rotate all doors or rotate every other door. -
Page 29: Powering For The Dw-R
• Applying power to the entire system • Powering the machine Powering down the system includes: • Powering down the machine • Removing power from the entire system Steps Before Powering the DW-R Don’t Forget Air ON Closed Gates and E-Stops Power the Main Electrical Cabinet... -
Page 30: Powering The Dw-R
Powering for the DW-R Powering the DW-R ‘Follow the steps below to power down the machine. See Figure 2-3. Pull the green switch out the ON position. The switch will light-up. Control Circuit Push the green button to “boot up” the machine. - Page 31 Powering for the DW-R Push in the Control Circuit Button Push the Stop Button Turn the Main Power Switch to OFF Power Control Steps FIGURE 2-3. Powering for the DW-R...
-
Page 32: About Emergency Shutdown And Recovery
About Emergency Shutdown and Recovery About Emergency Shutdown and Recovery Important: Before operating this machine, learn all safety precautionary controls on the machine. Depending on the model of machine, there are emergency shutdown ( ) switches located at E-Stop key points around the machine. switches are to be used when the machine is out of control or is about to damage per- E-Stop sonnel or equipment. -
Page 33: About The Setting-Up The Dw-R Interface
Sets up to 5 Return to the Enter Quantity of the Doors Main Menu After Set DW-R is completed, the machine will continue to the next set until Note: all Sets are finished. About the Setting-Up the DW-R Interface... -
Page 34: About The Dw-R User Interface Screen
About the DW-R User Interface Screen About the DW-R User Interface Screen This section describes the user interface screens. The user interface allows the operator to use a touch screen to control the door cutting process, auto-run and manually run the door, store door... -
Page 35: About The Main Screen
About the DW-R User Interface Screen About the Main Screen Below is a screen capture of on the . Selections are described below. Main Screen DW-R Auto/Manual: Normal Rotate: Feed Forward: Manual Rotate: Select to toggle Press to have doors... -
Page 36: About The Troubleshooting Menu
About the DW-R User Interface Screen About the Troubleshooting Menu Use this menu to check the operation of the sensors in the machine.With this tool, outputs and inputs can be viewed in there on and off states. The indicators on the screen show the area and location of the sensors. -
Page 37: About The Output/Input Menus
About the DW-R User Interface Screen About the Output/Input Menus These menus display the status of the Outputs and Inputs of the PLC. Refer to the machine Elec- trical Drawing for troubleshooting down to the node. OUTPUT INDICATORS Square displays like this show the status of the controller outputs. - Page 39 Tour of the DW-R CHAPTER 3 This chapter describes components, assemblies, and the user interface of the Kval DW-R System. The content is geared to help operators understand the basic operation of the machine. Section Name Summary Page Overview of Machine Top view of the machine with call-outs.
-
Page 40: Top View Of Dw-R
Tour of the DW-R Tour of the DW-R This section shows the location and describes the main components of the DW-R Auto -Rotate Sta- . Included are Top, In-Feed, and Out-Feed Views tion Top View of DW-R Sensors: Optical Sensors... -
Page 41: In-Feed View Of Dw-R
Tour of the DW-R In-Feed View of DW-R Feed Drive: Sensors: Shaft Moves Rollers Forward and Reverse. Starts Rollers to feed Door in. Cross Over Cylinders: Raises Belt to move door to Fence. Rotate Gear: Gear drives Door Rotation Air Solenoid Bank: Solenoids are driven by PLC. -
Page 42: Out-Feed View Of Dw-R
Tour of the DW-R Out-Feed View of DW-R Sensors: Cross Over Cylinders: End of Machine. Raises Belt to move door to Fence. Feed Motor: Motor drives the feed through Rollers in forward and reverse direction Switch: Lift Limit Rotate Cylinder:... -
Page 43: About The Operator Station
Rotate Table, 990-FX, Ball Catch Machine DW-R the operator control of the machine. Control Circuit Powers up the machine Start/Stop Touch Screen Starts the machine Process Operator Station (DW-R) FIGURE 3-8. About the Operator Station... -
Page 44: About The Main Electrical Panel
About the Main Electrical Panel About the Main Electrical Panel This section provides descriptions of the components located in the Main Electrical Panel. is located on the right side of the electrical enclosure. Main Electrical Panel Each area is identified in Figure 3-9 and descriptions of the components follow in the next sec- tions. -
Page 45: Plc Section
About the Main Electrical Panel PLC Section section of the predominately contains components for the on-board Electrical Panel industrial computer. Table 3-2 and Figure 3-10 show the locations and descriptions of the components in the sec- tion. Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion. -
Page 46: Voltage Input Section
About the Main Electrical Panel PLC Section Descriptions TABLE 3-2. Component Description E-Hub Adds extra ports to the EtherCAT connections. 24 VDC Power Supplies VDC power supplies that supplies DC Voltage to assemblies in the machine system. DC Volt Analog Terminals Connections for DC voltages (24 VDC/48VDC) in the Electrical Panel. -
Page 47: Vfd Section
About the Main Electrical Panel TABLE 3-3. Component Description Machine Power Input Power is suppled to the top of the Disconnect. The middle of the switch is attached to the main power lever. The PDR is a contactor. Contactors are designed to control and suppress the arc produced when interrupting heavy motor currents. -
Page 48: Vfd Reset Buttons
About the Main Electrical Panel Transformer Section Descriptions TABLE 3-4. Component Description Control Transformer The Control Transformer steps down the incoming source vac to DW-RDW-R0/ DW-R20 Vac to be routed through the panel. The Variable Frequency Drivers supply speed control to motors on the machine. -
Page 49: Description Of The Six Light Panel
Description of the Six Light Panel Description of the Six Light Panel The six lights on this panel indicate the status of the system. The Sequence that the lights activate is as follows: Control Power Overload Relay E-Stop Stop Start 24VDC Description of the Six Light Panel 3-10... -
Page 50: About The Pneumatic System
Air, Muffler, 3/8 NPT, High Flow Exhaust;. Deadens the sound of the air exhaust. Filter Filter, DW-R/2” NPT Port With Auto Drain. Filters shop air to create Clean Dry Air to deliver to the machine. Regulator Regulator, DW-R/2” NPT Port With Back Flow Mechanism With Gauge. -
Page 51: 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.The solenoids are connected to the top of the manifold. Labels indicating their function and con- nections are attached to the solenoid body. Use this information to troubleshoot the system if nec- essary. -
Page 52: Pneumatic System Overview
Pneumatic System Overview Pneumatic System Overview Figure 3-17 shows the locations components of the Pneumatic System. Figure 3-17 can be considered as an overview of the pneumatic system. Always Note: refer to the for defined values. Machine Air Print Crossover Pop-Ups Pop Up Cylinder Moves Rotate Assembly Up Rotate Cylinder... -
Page 53: About Dw-R 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 3-19. 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 54: About Proximity Sensors
About DW-R Sensors About Proximity Sensors Metal sensors in machinery are frequently employed as part of quality control measures. They're utilized to 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 identify- ing any unexpected metal pieces in the processed items. -
Page 55: Sensor Locations
Sensor Locations Sensor Locations Figure 3-23 shows the locations of sensors on the machine. Metal proximity sensors provide feed- back of the locations of the assemblies. The photo sensors track the door progress though the machine. See the for all locations. Note: Electro Mechanical Map At Fence Sensor... - Page 60 http://www.kvalinc.com...
Need help?
Do you have a question about the DW-R and is the answer not in the manual?
Questions and answers