Kval 979-2 Manuals

Manuals and User Guides for Kval 979-2. We have 6 Kval 979-2 manuals available for free PDF download: Operation And Service Manual, Operation Manual, System Reference Manual, Service Manual, Manual

Kval 979-2 Operation Manual (108 pages)

Miter Trim Saw System

Brand: Kval | Category: Industrial Equipment | Size: 20 MB

Proprietary Notice
2
Contacting KVAL
2
Technical Service Support
3
Sales Support
3
Table of Contents
5
Introduction to the 979-2 System
9
Overview of the
10
About this Manual
11
Operation Manual
11
Service Manual
11
Access Manuals and Videos Easily
12
QR Code
12
Safety First
13
Safety Sheet Sign-Off Sheet
13
Safety Terminology of Labels
13
Safety Guidelines
14
Training
14
Protective Gear
14
When the Machine Is Powered and Running
14
Compressed Air
15
Electrical
15
Pinch Points
17
Before Conducting Maintenance
17
Laser Warnings
18
Compliance with Codes and Regulations
18
Other Hazard Control Action
18
Follow Your Company's Safety Procedures
18
Lockout Tagout Air Supply
19
Lockout/Tagout Guidelines
20
Follow the P-R-O-P-E-R Lockout Rule of Thumb
20
Lockout/Tagout Procedure
21
Before Lockout/Tagout: Inspect the Machines
21
Lockout/Tagout Power
21
Lockout/Tagout Air Supply
22
Start Maintenance
22
Post Maintenance Steps
23
Zero-Energy to Start-Up
24
Inspect
24
Clean up
24
Replace Guards
24
Check Controls
24
Remove Locks
24
Perform Visual Checks
24
Close the Cage Gate
25
Getting Help from Kval
26
Kval Return and Warranty Policy
27
Send the Item
27
Acceptance of Return
27
Refund Turnaround Time
27
Kval Errors
27
Customer Errors
28
Shipper Errors
28
Warranty Replacement Parts
28
Safety Sign-Off Sheet
29
A Note to the Operator
29
Operation of the 979-2
31
Chapter 2 At a Glance
31
About Modes
32
Header Mode
32
RH Leg Mode
33
LH Leg Mode
33
Straight Cut Mode
33
Powering Steps for the 979-2
34
Steps before Powering the 979-2
34
Don't Forget
34
Powering the
35
Home the 979-2
35
Powering down the 979-2
36
About Safety Controls
37
About the E-Stop System
37
To Activate the E-Stop System
38
To Resume Normal Operation after an E-Stop
38
Before Processing a Casing
39
Adjustment Procedures
40
Special Adjustments
43
About the Brushes
43
Adjusting the Brushes
43
About the Center Rest
44
Processing a Casing
45
Summary of the Interface
48
Main Screen
48
Modify Presets Screen
49
Calibration Screen
49
Diagnostics Screen
50
Universal Displays
51
About the Jump, Reset, and Home Buttons
51
Machine Feed Back
52
Main Screen
53
About the Mode Buttons
53
About the Preset Buttons
54
About Manual Operation
55
Manual Mode On/Off
56
Exit Application
56
How to Open the Operator Interface from Windows
56
Movable Head Buttons
57
Saw Adjust Buttons
58
Button Selection
58
Burn in Chipout Button
59
Put the Saw into Position and Remove the Chipout Block
59
Process to Burn in a Chipout Block
61
Process to Remove and Replace the Saw Blade
62
Tools
62
Procedure to Change the Saw Blade
62
About the Calibration Screen
67
Enter a Positive or Negative Number
67
Measure the Casings
68
Entering Calibration Data
69
About Calibrating All Bevels
70
About Calibrating the Straight Mode (0°- 0°)
70
About Calibrating the RH Leg Mode (45°-0°)
71
About Calibrating the LH Leg Mode (0°-45°)
71
About the Modify Presets Screen
72
About Programming the Preset Buttons
72
Diagnostic Screen
75
Tour of the 979-2 Machine
77
Operator's Tour
78
Top View
78
Operator Controls
79
About the Operator Interface
80
About the Foot Pedal
81
About the E-Stop System
81
Front Section
82
Back Section
82
About the Feed System
84
About the Width System
84
About the Feed System
85
Adjustable Feed Assemblies
86
About the Saw Cutter Heads
87
About the Electrical Panel
89
PLC Section
90
How to Use the VPN
91
Analog Voltage Section
92
Power Input Section
92
Servo Drive and VFD Section
93
Electrical Panel Connections
96
About Network Topography
97
Ethercat Box Fixed Head
97
Ethercat Box Movable Head
98
About the Light Tower
99
About the Pneumatic System
100
About the FRL
100
About the Valve Banks
101
Pneumatic System Overview
102
About Sensors
103
About Photo Sensors
103
About Proximity Sensors
104
979-2 Sensor Locations
105

Kval 979-2 Operation And Service Manual (112 pages)

Miter Trim Saw System

Brand: Kval | Category: Saw | Size: 13 MB

Table of Contents
5
Chapter 1 At a Glance

9
- Overview of the 979-2 Miter Trim Saw System
  10
  - About this Manual
    11
- Safety First
  12
  - Safety Sheet Sign-Off Sheet
    12
  - Safety Terminology of Labels
    12
  - Safety Guidelines
    12
- Lockout-Tagout Guidelines
  16
  - Follow the P-R-O-P-E-R Lockout Rule of Thumb
    16
- Lockout Tagout Procedure
  17
  - Pre-Steps before Lockout Tagout
    17
  - Lockout Tagout Power
    17
  - Lockout Tagout Air Supply
    18
  - Start Maintenance
    18
  - Post Maintenance Steps
    18
- Zero-Energy to Start-Up
  19
- Getting Help from KVAL
  21
  - On-Line Help
    21
  - Product Return Procedure
    21
- Safety Sign-Off Sheet
  24
  - A Note to the Operator
    24
Chapter 2 Operation of the

26
- Operator's Tour
  27
  - In-Feed Section
    28
  - Foot Pedal
    28
  - Operators Station
    29
  - Operators Station (Small Platform Screen)
    29
  - The Starts Saws Button
    30
  - Out-Feed
    30
- About the Electrical Panels
  31
  - Main Electrical Panel with VPN
    31
  - Main Electrical Panel (before VPN)
    32
- About Using the VPN
  33
- About the Safety Curtain
  34
- Description of the Six Light Panel
  35
  - About Sensors
    36
- Quick Start
  37
  - Home the 979-2
    37
  - Powering Operations for the 979-2
    39
  - How to Power up the 979-2
    39
  - Home the 979-2
    40
  - How to Power down the 979-2
    41
  - Emergency Shutdown and Recovery
    41
  - About Modes
    42
- Mechanical Set up
  43
- Description of User Interface Screens
  45
- About the Setup Screens
  52
  - About Calibration Data
    52
  - Running a Reference Cut
    52
  - About Motion of Servo Motor
    52
  - Entering Calibration Data
    53
  - About the Machine Calibration Screen
    54
  - About Assigning a Pre-Set
    56
- About Manual Operation and Chipout Routine
  57
- Diagnostic Screen
  59
Chapter 3 System IT Administration

61
- About the 979-2 Computer
  61
- Connections on the PLC
  61
- Backing up the Computer
  61
Chapter 4 Maintenance of the

65
- Maintenance Schedule
  66
- Maintenance NO-GOES
  68
- Lubrication Schedule
  69
  - Typical Lucubration Kit
    69
- Lubrication Requirements
  70
  - Pillow Block Bearing Housings
    70
  - Flange Bearing Housings
    71
  - Ball Rail Bearing
    71
  - About Taper Bearings
    72
  - Tapered Bearing Housings
    72
  - Ball Screw Nut
    73
  - Ball Screw Drive Assembly
    73
  - Pulley and Idler Shafts
    74
- Lubrication Points on the 979-2
  75
  - Lubrication Points Heads
    76
- Replacing the Chipout Block
  77
- Replacing Saw Blades
  78
  - Remove the Saw
    78
- Description of Air Input System
  80
  - Air Input with Lubrication
    80
  - Air Line Without Lubricator
    81
- Mechanical Adjustments
  82
  - 979-2 Guard Placements and Purpose
    82
    
    Feed Dog Adjustment Procedure
    84
Chapter 5 Troubleshooting the

87
- About Motion Control
  88
- Troubleshooting Basics
  93
  - Using Sensors to Trouble Shoot
    93
- Location of Sensors on 979-2
  94
- Location of Sensors on
  94
- Troubleshooting Electrical Problems
  95
  - If the Power Stops During Normal Operation
    95
  - Troubleshooting with the Status Light Panel
    96
  - Control Power Light off
    98
  - Overload Relay Light off
    99
  - E-Stop Light off
    99
  - Stop Light off
    99
  - Start Light off
    100
  - 24VDC Light off
    100
  - About VFD Troubleshooting
    101
  - Error Checking on the Variable Frequency Drives
    101
  - Using the Reset Buttons
    101
- Troubleshooting the Air Cylinders
  102
  - Adjusting Cylinder Extension Speed
    103
  - Adjusting Cylinder Retraction Speed
    103
- Adjusting Limit Switches
  104

Kval 979-2 System Reference Manual (102 pages)

Miter Trim Saw

Brand: Kval | Category: Saw | Size: 9 MB

Contacting KVAL
3
Table of Contents
5
CHAPTER 1 Introduction

9
- Overview of the
  9
- Safety First
  11
- Safety Guidelines
  11
- Lock out Procedure
  12
- To Lock out the 979-2
  12
- Lockout and Tagout Guidelines
  13
- Follow the P-R-O-P-E-R Lockout Rule of Thumb
  13
- Zero-Energy Start-Up
  14
- Zero-Energy State to Start-Up to Operating State
  14
- Start-Up
  14
- Inspect
  14
- Clean up
  14
- Replace Guards
  14
- Check Controls
  14
- Remove Locks
  14
- Execute Visual Checks
  14
- 979-2 Guard Placements and Purpose
  16
- Initial Set up
  17
- Trubolt Wedge Anchor
  18
- Installation Instructions
  18
- Electrical Connections Overview
  19
CHAPTER 2 Operation

21
- Machine Tour
  23
- Quick Start
  25
- Turning the 979-2 on and off
  27
- Powering up the
  27
- Powering up the System Includes
  27
- To Power up the 979-2
  27
- Powering down the 979-2
  27
- To Power down the 979-2
  28
- Emergency Shutdown and Recovery
  28
- To Resume Normal Operation after an E-Stop
  28
- Modes
  29
- Mechanical Set-Up
  30
- Presets
  32
- Quick Access Preset Selection
  32
- Direct Access Preset Selection
  33
- Preset Storage
  34
- Manual Length Entry
  35
- Touch Screen Interface
  37
- Ok to Move
  37
- Run Screen
  38
- Preset Screen
  39
- Length / Preset Screens
  40
- Keypad Fractional Screen
  41
- Keypad Quantity Screen
  41
- Length Only Screen
  42
- Machine Data
  43
- Clamp Setup
  44
CHAPTER 3 Calibration

45
CHAPTER 4 Maintenance

47
- Maintenance Schedule
  48
- Daily
  48
- Weekly
  48
- May and December Checkups
  49
- Lubrication Requirements
  50
- Linear Bearings
  50
- Flange Bearing and Pillow Blocks
  50
- Approved Lubrication Products for Lubricators
  50
- Gear Motor Lubrication Requirements
  50
- Ball Screws
  50
- Adjusting the Air Line Lubricator (Not Available on All Machines)
  51
- Grease Points
  52
- Main Frame Bottom View
  52
- Fixed Head
  53
- Movable Head
  54
- Cut Depth Set-Up
  55
- Adjusting the Saw Height
  55
- Feed Cylinder Replacement and Feed Dog Adjustment Procedure
  61
CHAPTER 5 Troubleshooting

65
- Troubleshooting the Air Cylinders
  66
- Adjusting Cylinder Extension Speed
  67
- Adjusting Cylinder Retraction Speed
  67
- Troubleshooting Electrical Problems
  68
- If the Power Stops During Normal Operation
  68
- Troubleshooting with the Status Light Panel
  69
- Adjusting Limit Switches
  72
- Troubleshooting Photo Detectors
  73
- Getting Help from Kval
  74
- Product Return Procedure
  74
- Touch Screen Troubleshooting
  75
- Maintenance Screen
  75
- Machine Status
  76
- Sequence Does Not Complete
  77
- Start Sequence (Feed)
  78
- Saws Do Not Extend
  79
- Saws Do Not Start
  80
- Heads Do Not Adjust
  81
- PLC Input-Bit Status
  82
- PLC Output-Bit Status
  83
- PLC M-Bit Status
  84
- GALIL IO Status
  85
- Kerf Saw Sequence (Optional)
  86
- Technical Support
  87
- Servo Trouble Shooting
  88
- Limit - Switch Timing
  89
- General Process Description
  89
- 979-2 X Axis Limit Switch Timing
  90
- Set Minimum Cut
  91
- Part Locations
  93
- General Top View
  93
- Right or Movable Head
  94
- Left or Fixed Head
  95
- Heads - Bottom View
  96
- Top View and Main Valve Bank
  97
- Warranty
  99

Kval 979-2 Service Manual (66 pages)

979-2 Miter Trim Saw System

Brand: Kval | Category: Saw | Size: 2 MB

Table of Contents
5
Chapter 1 At a Glance

7
- Overview of the 979-2 Miter Trim Saw System
  8
- About this Manual
  9
- Safety First
  10
- Safety Sheet Sign-Off Sheet
  10
- Safety Terminology of Labels
  10
- Safety Guidelines
  10
- Lockout-Tagout Guidelines
  14
- Follow the P-R-O-P-E-R Lockout Rule of Thumb
  14
- Lockout Tagout Procedure
  15
- Pre-Steps before Lockout Tagout
  15
- Lockout Tagout Power
  15
- Lockout Tagout Air Supply
  16
- Start Maintenance
  16
- Post Maintenance Steps
  16
- Zero-Energy to Start-Up
  17
- Getting Help from Kval
  19
- Kval Return and Warranty Policy
  20
- Send the Item
  20
- Acceptance of Return
  20
- Refund Turnaround Time
  20
- Kval Errors
  20
- Customer Errors
  21
- Shipper Errors
  21
- Warranty Replacement Parts
  21
- Safety Sign-Off Sheet
  23
- A Note to the Operator
  23
- Maintenance of the 979-2
  25
- Maintenance Schedule
  26
- Maintenance NO-GOES
  28
- Lubrication Schedule
  29
- Typical Lucubration Kit
  29
- Lubrication Requirements
  30
- Pillow Block Bearing Housings
  30
- Flange Bearing Housings
  31
- Ball Rail Bearing
  31
- About Taper Bearings
  32
- Tapered Bearing Housings
  32
- Ball Screw Nut
  33
- Ball Screw Drive Assembly
  33
- Lubrication Points on the 979-2
  34
- Lubrication Points Servo Assembly
  34
- Lubrication Points Heads
  35
- Replacing the Chipout Block
  36
- Chipout Replacement Process
  36
- Process to Burn in a Chipout Block
  37
- Example of a Newly Burned in Chipout Block
  37
- Mechanical Adjustments
  38
- 979-2 Guard Placements and Purpose
  38
- Feed Dog Adjustment Procedure
  39
- Description of Air Input System
  42
- Air Input with Lubrication
  42
- Air Line Without Lubricator
  43
- Troubleshooting the 979-2
  45
- About Motion Control
  46
- Basic Control Circuit
  46
- Typical Positioning Systems
  48
- Troubleshooting Basics
  51
- Using Sensors to Trouble Shoot
  51
- Location of Sensors on 979-2
  52
- Troubleshooting Electrical Problems
  53
- If the Power Stops During Normal Operation
  53
- Troubleshooting with the Status Light Panel
  54
- About VFD Troubleshooting
  59
- Troubleshooting the Air Cylinders
  60
- Adjusting Cylinder Extension Speed
  61
- Adjusting Cylinder Retraction Speed
  61
- Adjusting Limit Switches
  62

Kval 979-2 Operation Manual (62 pages)

Miter Trim Saw System

Brand: Kval | Category: Saw | Size: 2 MB

Table of Contents
5
Chapter 1 At a Glance

7
- Overview of the 979-2 Miter Trim Saw System
  8
- About this Manual
  9
- Safety First
  10
- Safety Sheet Sign-Off Sheet
  10
- Safety Terminology of Labels
  10
- Safety Guidelines
  10
- Lockout-Tagout Guidelines
  14
- Follow the P-R-O-P-E-R Lockout Rule of Thumb
  14
- Lockout Tagout Procedure
  15
- Pre-Steps before Lockout Tagout
  15
- Lockout Tagout Power
  15
- Lockout Tagout Air Supply
  16
- Start Maintenance
  16
- Post Maintenance Steps
  16
- Zero-Energy to Start-Up
  17
- Getting Help from Kval
  19
- Kval Return and Warranty Policy
  20
- Send the Item
  20
- Acceptance of Return
  20
- Refund Turnaround Time
  20
- Kval Errors
  20
- Customer Errors
  21
- Shipper Errors
  21
- Warranty Replacement Parts
  21
- Safety Sign-Off Sheet
  23
- A Note to the Operator
  23
- Operation of the 979-2
  25
- Quick Start
  26
- Powering Operations for the 979-2
  28
- How to Power up the 979-2
  28
- Home the 979-2
  29
- How to Power down the 979-2
  29
- Emergency Shutdown and Recovery
  29
- About Modes
  30
- Mechanical Set up
  31
- Description of User Interface Screens
  33
- Machine Feed Back
  34
- About Lock-Outs (Option)
  34
- Main Screen
  35
- About the Software Start Saws Button (Older Machines)
  35
- About the Setup Screens
  38
- About Calibration Data
  38
- Running a Reference Cut
  38
- About Motion of Servo Motor
  38
- Entering Calibration Data
  39
- About the Machine Calibration Screen
  40
- About Assigning a Pre-Set
  42
- About Manual Operation and Chipout Routine
  43
- About the Chipout Routine
  44
- Diagnostic Screen
  45
- Tour of the 979-2
  47
- Operator's Tour
  48
- Front Section
  49
- About the Dog Feeds
  49
- About View Ports
  50
- Foot Pedal
  50
- Operation Station
  51
- The Starts Saws Button
  51
- About the Back Section
  52
- About the Electrical Panels
  53
- Main Electrical Panel with VPN
  53
- System IT Administration
  54
- About the 979-2 Computer
  54
- Connections on the PLC
  54
- About the Thermal (Brake) Resistor
  55
- About Using the VPN
  55
- Description of the Six Light Panel
  56
- About Sensors
  57

Kval 979-2 Manual (12 pages)

Miter Trim Saw System

Brand: Kval | Category: Saw | Size: 1 MB

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