Innovation, Quality & Honesty 979-2 Miter Trim Saw System … · 2019-05-24 · 979-2 Innovation, Quality & Honesty 979-2 Miter Trim Saw System Reference Published: 4/24/07

Innovation, Quality & Honesty

979-2 MiterTrim SawSystem ReferencePublished: 4/24/07

979-2

979-2

Proprietary Notice

This document contains confidential and trade secret information, which is proprietary to Kval, Inc. (“Kval”), and is protected by laws pertaining to such materials. This document, the information in this document, and all rights thereto are the sole and exclusive property of Kval, are intended for use by cus-tomers and employees of Kval, and are not to be copied, used, or disclosed to anyone, in whole or in part, without the express written permission of Kval. For 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.

Copyright 2006 Kval Incorporated. All rights reserved.

KVAL 2006 and 979-2 are trademarks of Kval, Incorporated.All other products are trademarks or registered trademarks of their respective holders, all rights reserved. Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated.

Contacting KVAL

Customer Service: For further information about this manual or other Kval Incorporated products, contact the Customer Support Department

• http://www.kvalinc.com/customer_service.html (lists all the representatives, including email addresses and phone numbers)

• Mailing address:Customer Support DepartmentKval Incorporated825 Petaluma Boulevard SouthPetaluma, CA 94952

• Phone and Fax:In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Business hours:Technical Support: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through FridayParts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday(Other sales related inquiries: http://www.kvalinc.com/contact_us.html)

• Email: [email protected] •

Your Feedback is Welcome: To help us design products that make your job easier and your business more successful, we'd like to gain your perspective about your user experience with our product - that is, the manual, the machinery, the software, etc. What was easy or difficult to use or to learn? If you could change something about the design, what would it be? Please email your comments and sugges-tions for improvement to [email protected]. (NOTE: This is not a way to get customer sup-port. For that, please refer to the Customer Service contact information above.) Thank you!

979-2 a

b 979-2

Proprietary Notice ..........................................................................................aContacting KVAL ..........................................................................................a

CHAPTER 1 Introduction ....................................................................................1Overview of the 979-2 ...................................................................................1

Safety First! ..........................................................................................................3Safety Guidelines ........................................................................................3

Lock Out Procedure .......................................................................................4To lock out the 979-2 ..................................................................................4

Lockout and Tagout Guidelines .....................................................................5Follow the P-R-O-P-E-R lockout rule of thumb. ..........................................5

Zero-Energy Start-Up ..........................................................................................6Zero-Energy State to Start-Up to Operating State .........................................6

Start-up ........................................................................................................6Inspect .........................................................................................................6Clean Up .....................................................................................................6Replace Guards ...........................................................................................6Check Controls ...........................................................................................6Remove Locks ............................................................................................6Execute Visual Checks ...............................................................................6

979-2 Guard Placements and Purpose .................................................................8Initial Set up .........................................................................................................9

Trubolt Wedge Anchor .............................................................................10INSTALLATION INSTRUCTIONS .......................................................10

Electrical Connections Overview ................................................................11

CHAPTER 2 Operation .....................................................................................13Machine Tour .....................................................................................................15Quick Start .........................................................................................................17Turning the 979-2 On and Off ...........................................................................19

Powering Up the 979-2 ................................................................................19Powering up the system includes: .............................................................19To Power Up the 979-2 .............................................................................19

Powering Down the 979-2 ...........................................................................19To Power Down the 979-2 ........................................................................20

Emergency Shutdown and Recovery ...........................................................20To Resume Normal Operation after an E-Stop ............................................20

Modes .................................................................................................................21Mechanical Set-up .............................................................................................22Presets ................................................................................................................24

Quick Access preset selection ...................................................................24

979-2 c

Direct Access preset selection ..................................................................25Preset Storage ...............................................................................................26Manual Length Entry ...................................................................................27

Touch Screen Interface ......................................................................................29OK TO MOVE .............................................................................................29Run Screen ...................................................................................................30Preset Screen ................................................................................................31Length / Preset Screens ................................................................................32Keypad Fractional Screen ............................................................................33Keypad Quantity Screen ..............................................................................33Length Only Screen .....................................................................................34Machine Data ...............................................................................................35Clamp Setup .................................................................................................36

CHAPTER 3 Calibration ...................................................................................37

CHAPTER 4 Maintenance .................................................................................39Maintenance Schedule .......................................................................................40

Daily .............................................................................................................40Weekly .........................................................................................................40May and December Checkups .....................................................................41

Lubrication Requirements ..................................................................................42Linear Bearings .........................................................................................42Flange Bearing and Pillow Blocks ............................................................42Approved Lubrication Products for Lubricators .......................................42Gear Motor Lubrication Requirements .....................................................42Ball Screws ...............................................................................................42Adjusting the Air Line Lubricator (not available on all machines) ..........43

Grease Points ...............................................................................................44Main Frame Bottom View ........................................................................44Fixed Head ................................................................................................45Movable Head ...........................................................................................46

Cut Depth Set-up ...............................................................................................47Adjusting the Saw Height ............................................................................47

Feed Cylinder replacement and Feed Dog Adjustment procedure ....................53

CHAPTER 5 Troubleshooting ............................................................................57Troubleshooting the Air Cylinders ....................................................................58

Adjusting Cylinder Extension Speed: ..........................................................59Adjusting Cylinder Retraction Speed: ........................................................59

Troubleshooting Electrical Problems .................................................................60

d 979-2

If the Power Stops During Normal Operation ............................................60Troubleshooting with the Status Light Panel ...............................................61

Adjusting Limit Switches ........................................................................64Troubleshooting Photo Detectors .......................................................................65Getting Help from Kval .....................................................................................66

Product Return Procedure ............................................................................66Touch Screen Troubleshooting ..........................................................................67

Maintenance Screen .....................................................................................67Machine Status ........................................................................................68

.....................................................................................................................68Sequence does not complete .......................................................................69Start Sequence (Feed) .................................................................................70Saws do not extend .....................................................................................71Saws do not start .........................................................................................72Heads do not adjust .....................................................................................73PLC Input-Bit Status ...................................................................................74PLC Output-Bit Status ................................................................................75

.....................................................................................................................75PLC M-Bit Status .........................................................................................76GALIL IO Status .........................................................................................77Kerf Saw Sequence (optional) ....................................................................78Technical Support ........................................................................................79Servo Trouble Shooting ...............................................................................80Limit - Switch Timing .................................................................................81

General process description: .....................................................................81979-2 X Axis Limit Switch Timing .............................................................82Set Minimum Cut .........................................................................................83

Part Locations ....................................................................................................85General Top View .....................................................................................85Right or Movable Head .............................................................................86Left or Fixed Head ....................................................................................87Heads - Bottom View ...............................................................................88Top View and Main Valve Bank ..............................................................89

Warranty .............................................................................................................91

979-2 e

f 979-2

CHAPTER 1 Introduction

This chapter provides a description of the 979-2 product and identifies safety guidelines that you should follow to ensure safety of personnel and equipment. Information includes:

• Overview of the 979-2• Getting Started-Uncrating and Anchoring the 979-2• Electrical Connections Overview• Safety Guidelines• Lock-Out Procedure• Tag-Out Guidelines• Zero-Energy Start-Up• Zero-Energy State to Start-Up Operating State• 979-2 Guard Placements and Purpose

Overview of the 979-2

The Kval Model 979-2 Miter Trim Saw is designed to cut door stops and casing materials up to 26 pieces per minute. Similar to a portable powered miter saw, the blades of the 979-2 cut from above the work pieces through the material face to achieve the best quality possible with all types of moulding materials, including pre-finished casing. Air consumption is just 8 CFM.The hopper feed system accommodates material up to 4½ inches wide and from 12½ inches to 100 inches in length. The precision parallel feed system guarantees parallel indexing of work pieces under-neath saw blades. Saw motors are three-phase, 3HP.Saws pivot between either 0- or 90-degree positions. The CNC index system will automatically com-pensate for cut length by adjusting the distance between saws.Notable features of this machine are its touchscreen control panel and CNC index system.All machine programming is done from the 979-2 operator's station touchscreen interface.The touchscreen panel features on-board diagnostic screens that allow the operator to quickly and easily identify the source of any errors or failures, even after they have occurred.Operation DescriptionTrim material is placed in the hopper. The feed system then moves the material to the saws where the end cuts are made. The material is then moved to the kerf saws (optional) and out of the machine.

979-2 1

Introduction

2 979-2

Safety First!

Safety First!The 979-2 is a powerful electro-mechanical motion control system. You should test your motion system for safety under all potential conditions. Failure to do so can result in damage to equipment and/or seri-ous injury to personnel.

Safety Guidelines

In addition to the caution and warning labels affixed to the 979-2 system, follow the guidelines below to help ensure the safety of equipment and personnel.

Guideline DescriptionSafety Training Ensure that all employees who operate this machine are aware of and adhere to all

safety precautions posted on the machine and are trained to operate this machine in a safe manner.

Protective Gear Never operate the machine without proper eye and ear protection.Entering the Safety Cage When the machine is on:

• Never reach hands beyond safety cage. Servo motors can unexpectedlymove quickly and out of control.

• Do not clear slugs out of the machine while it is running.• Never perform any maintenance while machine is running.• Never clean the machine while running.• Never walk away from the machine while running.

Compressed Air .

Electrical Electrical circuitry on this machine is protected by an approved lockable disconnect circuit. In addition to this equip-ment, you must install an approved disconnect for the electri-cal power supplying this machine.

When opening the cabinet you must first turn off the discon-nect switch. When the cabinet door is open there is still power on the top side of the disconnect switch. All maintenance and repairs to electrical circuitry should only be performed by a qualified electrician.

Before Conducting Maintenance

Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tag out, or lock out the electrical and air pressure systems. This should be done in accordance with the state and/or federal code requirements.

Compliance with Codes and Regula-tions

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

The compressed air system connected to this machine should have a three-way air valve for shut-off and pressure relief. The air supply providing the pressure to this machine also has a three-way air valve for the supply line. All cylinders on machine are under high pressure and can be very dangerous when activated. Before performing any maintenance or repairs on machine turn the main air disconnect off. Lock out and tag out this connection.

Still has powerin OFF position

979-2 3

Lock Out 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 the 979-2 while it is powered down. During a lockout, you disconnect all power and shut off the air supply. Be sure to use the tagout guidelines noted below.

To lock out the 979-2

1.Assess the equipment to fully understand all energy sources (multiple electrical supplies, air supplyand pressure, spring tension, weight shifts, etc.).

2.Inform all affected personnel of the eminent shutdown, and the duration of the shutdown.3.Obtain locks, keys, and tags from your employer’s lockout center.4.Disconnect powerNOTE:Always lock out electrical disconnects on both electrical cabinets

a.Turn the disconnect switches on the main electrical panel to the OFF position. Then pull outthe red tab and place a padlock through the hole. Place your tag on the padlock, as per the tagout guidelines below. (see example below)

b.Turn the disconnect switch on the larger high-frequency panel to the OFF position. Then pullout the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tagout guidelines below

Other Hazard Control Action

If you believe any part or operation of this machine is in violation of any health or safety regulation, it is your responsibility to immediately protect your employees against any such hazard and bring the matter to our attention for review and correction, if deemed advisable.

Additional detailed safety guidelines are included in the operating instructions of this manual. KVAL will be pleased to review with you any questions you may have regard-ing the safe operation of this machine.

When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided.

4 979-2

Safety First!

5.Turn the main air valve to the OFF position and place apadlock through the hole (see illustration.).NOTE: Place your tag on the padlock, as per the tagoutguidelines below.

6.Once the locks and tags are in place and all personnel areclear, attempt to operate the machine to ensure equipmentwill not operate. When maintenance or repairs are com-pleted, the person who performed the work must ensure alltools, spare parts, test equipment, etc., are completelyremoved and that all guards and safety devices areinstalled.

7.Before removing the locks and tags, the person whoattached them shall inspect the equipment to ensure thatthe machine will not be put in an unsafe condition when re-energized.

8.The lock and tag can now be removed (only by the person(s) who placed them), and the machine canbe re-energized.

9.The tags must be destroyed and the locks and keys returned to the lockout center.

Lockout and Tagout Guidelines

• Place a tag on all padlocks. On the tags, include yourname and date.

• These locks are only to be removed by the person onthe tag.

• If more than one person is working on the machine,then each additional person places a lock and tag oneach disconnect. You may only remove your own lockand tag.

• You may only remove your own lock and tag

NOTE: When many people are all working on the same machine you will need a multiple lockout device, such as the one shown here.

Follow the P-R-O-P-E-R lockout rule of thumb.

P...... Process shutdownR ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)O...... OFF! Shut off all power sources and isolating devicesP...... Place lock and tagE...... ENERGY: Release stored energy to a zero-energy stateR ...... Recheck controls and test to insure they are in the “OFF” state

979-2 5

Zero-Energy Start-UpZero-Energy State to Start-Up to Operating State

Starting the equipment properly is just as important as the lock-out/tag-out procedure in terms of safety.

Start-up

• Inspect• Clean up• Replace guards• Check controls• Remove locks• Execute visual checks

Inspect

When work is finished, the equipment must be inspected for proper adjustment before starting equip-ment.

Clean Up

All materials and debris must be cleaned up. Any combustible materials or old parts used during repairs must be cleaned and / or properly disposed of.

Replace Guards

Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, leave only that guard off.

Check Controls

Confirm that all switches are in the “OFF” position. In some cases, the machine can start automatically when energy is restored.

Remove Locks

Each person must remove his or her own lock and tag. This will ensure operators are in a safe place when the equipment is started.

Execute Visual Checks

If the equipment is too large to see all around it, station personnel around the area and sound the person-nel alarm before starting the equipment. If your operation is more complex, having many pieces of equipment and a lot of people, a comprehensive lock-out/tag-out procedure may involve additional steps. You will need to ask your supervisor about these procedures. A specific lock-out procedure may be posted at each machine. On larger or long-term maintenance or installation projects, the procedures should be explained to all participants and a copy of the procedures should be posted on-site for the duration of the work. Provisions which ensure protection during shift changes when contractor or out-side help is used must also comply with the lock-out/tag-out procedures. Comprehensive lock-out/tag-

6 979-2

Zero-Energy Start-Up

out may use a gang box or other system to ensure that locks are secure and not removed without autho-rization.Remember, lock-out/tag-out procedures work because you are the only one with the key to your lock. Proper lock-out/tag-out can save lives, limbs, and money. Help make your work environment safe for yourself and your fellow employees. Make sure you follow the P-R-OP-E-R lock-out/tag-out proce-dures, and that those around you do also.

YOUR LIFE MAY DEPEND ON IT.

979-2 7

979-2 Guard Placements and PurposeThe following information gives a description of the mechanism being guarded, and the hazard being guarded against.1.Saw Assembly Guard:Located on both saw carriages, covering the entire saw assembly. The saw assembly guard provides protection from possible amputation, broken bones, eye injury from dust and wood particles, cuts, and bruises. There are saw blade access doors on the back side of both guards. NEVER ACCESS SAW BLADES WHILE POWER IS ON!

• Removal and Replacement:There are four bolts securing each saw assembly guard. There are two bolts on the top of theguard(s), and two bolts at the base of the guard(s) toward the end(s) of the machine. Removal of thesaw assembly guard is a two-person job. Never attempt to remove the guard by yourself.

2.Belt Guard:Located on both saw carriages, INSIDE the saw assembly guard, toward the outboard front of the saw assembly. The belt guard protects the operator from getting hands caught between the belt and the belt pulleys. The guard provides protection from amputation, cuts, bruises, broken bones. NEVER ACCESS THE BELT GUARD WHILE POWER IS ON!

• Removal and ReplacementThere are two bolts securing each belt guard, located on the flange of the guard near the saw assem-bly springs. Removal of the belt guard requires the operator to first remove the saw assembly guard.

3.Feed Assembly Guard:Located on the inboard sides of both saw carriage feed dog assemblies. The feed assembly guard pro-tects the operator from getting hands caught inside the moving parts of the feed assembly. The guardprovides protection against possible amputation, cuts, bruises, broken bones. NEVER ACCESS THEFEED ASSEMBLY GUARD WHILE POWER IS ON!• Removal and Replacement

There are eight socket heads securing bolts on each of the two feed assembly guards. The fasteningbolts are located in two rows of four bolts on the ends of the guard(s), toward the front and back ofthe feed dog assembly.

4.Kerf Blade Guard (for optional Kerf Saw):Mounted directly over the kerf blade(s) on both kerf routers located on either end of the 979-2. Thekerf blade guard is designed to protect the operator from the kerf blade, whether or not the machine isoperating. The kerf blade guard protects the operator from possible amputation, eye injury from air-borne dust and wood particles, and cuts. NEVER ACCESS THE KERF BLADE GUARD WHILEPOWER IS ON!• Removal and Replacement

The Kerf Blade Guard(s) is secured by two bolts on either side of the kerf blade guard.NOTE: These guards are present only when the kerf saw option has been installed.

8 979-2

Initial Set up

Initial Set upYour new Kval machine arrives at your plant crated, banded, taped, with painted set collars on all shafts, keeping all of the precision moving parts secure during shipping.1.To protect against damaging the machine with the forklift, move the machine as close as possible to

the area where it will be stationed before removing it from the crate 2.Use caution when removing the machine from the crate. Any time the machine is lifted to remove the

skids, there is a chance that the machine could drop suddenly, which could damage the machine or injure people near the machine.

3.Remove all painted set collars from the shafts. Almost every shaft on the machine has set collars tosecure the moveable assembly mounted to the shafts.

4.Remove any tape securing the various buttons, switches and knobs.Level your Kval machine by put-ting metal shims underneath the corners of the base. Leave a clear shot from the bolt holes in the foot pads to your shop floor.

5.Once the machine is level, anchor it to the floor so that it won't move across the floor during operation.Kval recommends a ½-inch Red Head, Trubolt anchor in each of the foot pads.

979-2 9

Trubolt Wedge Anchor

INSTALLATION INSTRUCTIONS1.Drill a ½-inch hole, minimum of 6-inch depth. Clean hole.NOTE: Kval recommends drilling completely through the slab. If in the future the machine needs to be moved, remove the Red Head nut and pound the bolt flush with the floor surface.

2.Assemble anchor with nut and washer so that the top of the nut isflush with the top of the anchor. Drive anchor through material to be fastened so that nut and washer are flush with surface material.

3.Expand anchor by tightening nut 3 to 5 turns (torque requirement55 ft. lbs. for a ½-inch Red Head Trubolt

10 979-2

Initial Set up

Electrical Connections OverviewG round

M ain Panel

3-Phase input

W ithout K erf Saw s W ith K erf Saw s

S ingle-Phase H O T

(B lack W ire)

S ingle-Phase N E U T R A L

(W hite W ire)

3-Phase input

M ain Panel D isconnect PL CThe main electrical power is connected to the disconnect, located in the main electrical panel.

NOTE: The main electrical panel contains the PLC.

The 979-2 requires three phase power. Refer to the plant layout diagram or the brass information plate to determine the voltage required. If the 979-2 is equipped with kerf saws, an additional 120-volt source is required.

Current Requirements:

• 220 volts - 20 amps• 460 volts - 10 amps• 120 volts - 22 amps (Kerf saws option only)

979-2 11

12 979-2

CHAPTER 2 Operation

The following chapters explain normal operation of the 979-2.

979-2 13

Operation

14 979-2

Machine Tour

Machine Tour

Left or Fixed Head

Right or Movable HeadControl TransformerButton

Start MachineButton

E-StopButton

E-Stop Pull Cord

E-StopButton

(Optional)

979-2 15

16 979-2

Quick Start

Quick Start1.Power up the 979-2. See “Powering Up the 979-2” on page 19.2.Select a mode. See “Modes” on page 21.

3.Select a preset - See “Presets” on page 24. or manually enter a length - See “Manual Length Entry” onpage 27.t

4.Run a test board.• If test board length is OK, continue.• If test board length is not OK, run calibration. See “Calibration” on page 37.

5.Modify the preset for the desired quantity.

6.Load the hopper and start production by press-ing the Start Sequence foot pedal.

Pick one

R-1 R-3

R-12R-11R-10R-9

R-8R-7R-6R-5

R-4R-298.250 78.25096.250 80.250

96.250 78.250 96.500 98.000

78.750 81.000 98.000 96.500

Pick one

R-1 R-3

R-12R-11R-10R-9

R-8R-7R-6R-5

R-4R-298.250

Right4

50

78.250

78.250

78 + (1/4)

96.250 80.250

96.250 78.250 96.500 98.000

78.750 81.000 98.000 96.500

78.250

Ready to start (0 of 50)

Press Here

Hopper

979-2 17

18 979-2

Turning the 979-2 On and Off

Turning the 979-2 On and OffUse the procedures below for powering up and powering down the 979-2.

Powering Up the 979-2

Powering up the system includes:

• Applying power to the entire system• Starting the Control Circuit

To Power Up the 979-2

1.Check to make sure all three E-Stop buttons are out and the cable pull switch is in the RUN position.2.Make sure the electrical disconnect on both electrical cabinets are turned to the ON position.3.Pull out the CONTROL TRANSFORMER switch. It should light up.4.Push the START button.5.All lights on the status light panel on the electrical box should be illuminated.

6.The 979-2 will now go through the homing routine. The “O.K. toMove” popup will appear. The “OK to Move” button must beheld when the movable cutting head is moving.The 979-2 is now ready for work.

Powering Down the 979-2

Powering down the system includes:• Shutting down the control power• Removing power from the entire system

CONTROL POWER

OVERLOAD RELAY

E-STOP

STOP

START

24VDC

979-2 19

To Power Down the 979-2

1.Push in the CONTROL TRANSFORMER switch. This kills power to themachine. All status lights should be off.

2.Kval also recommends that you turn the disconnect switches on both electricalcabinets to OFF; this helps reduce possible damage resulting from powersurges from electrical storms.

Emergency Shutdown and Recovery

There are four emergency shutdown (E-Stop) switches located on the 979-2. • Three push buttons, located on the main electrical cabinet, the main control

panel below the touchscreen, and on the base of the movable cutting head. • One foot switch.• One cable pull switch-- the cable running around the entire base of the

machine (optional).The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.When an E-Stop switch is activated, power to the machine is killed.NOTE:The machine responds in the same way if you press the STOP button on the operator's station.

To Resume Normal Operation after an E-Stop

If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved:1.De-activate the E-Stop switch.

• For a push button, pull the E-Stop switch back out.• For the foot switch, remove foot from the switch.• For the cable pull switch, set to RUN.

2.Push the START button on the operator's station.

20 979-2

Modes

Modes

The 979 will cut in four different modes:• Left: Puts the Left Head at 0º and the Right Head at 45º.

• Head: Puts the Left Head at 45º and the Right Head at 45º

• Right: Puts the Left Head at 45º and the Right Head at 0º.

• Stop: Puts the Left Head at 0º and the Right Head at 0º

Left Head Right Head

979-2 21

Mechanical Set-up1.From the Main menu or the Preset screen press Clamp Setup. See “Clamp Setup” on page 36.1.Adjust both back hopper stops for a hopper width of roughly 1/8-inch larger than the stock.2.Adjust both front hopper stop's height to clear the stock by roughly 1/8-inch.3.Adjust the end stop. This adjustment sets the machine for minimum stock waste. End stop distance is

determined by the fixed head cutting angle:• For 45 degrees, set the end stop for the same distance as the stock width.• For 0 degrees, set the end stop distance for 0 inches.

4.Set the front edge clamp distance to the same as the stock width.5.Set the jamb clamp width air valves. For stock less than 3 ½ inches, the valve must be slid toward the

input side of the machine. For stock greater than 3 ½ inches, the valve must be slid toward the out-feedside of the machine.

6.On the Touch Screen press Start Saws, then Yes to confirm.NOTE: Wide jamb mode has better clamping ability than nar-row jamb mode; tighter clamping produces cleaner saw cuts. Wide jamb mode can be used on narrow stock. The disadvantage is that wide jamb mode is slower by about 3 boards per minute.

22 979-2

Mechanical Set-up

Front edge clamp indicator

Set to stock width distance.

Jamb clamp width air valves

• Slide back for stock width lessthan 3 1/2”

• Slide forward for stock widthgreater than 3 1/2”

Less than 3 1/2”

Greater than 3 1/2”

Rear Hopper Stop

Adjust rear hopper stop to set hopper width to 1/8” wider than stock.

Front hopper stop

Front hopper adjustment boltsEnd stop distance indicator.Set to stock width distance.

Adjust front hopper stop height to clear stock by app. 1/8”

979-2 23

PresetsThe 979 has the ability to save up to 99 presets for each mode. The are two methods for accessing pre-sets. Quick Access method from the Preset screen or Direct Access method from the Length / Preset screen.

Quick Access preset selection

1. From the Main menu select the desired mode.2. Select the desired preset from the preset field.3.Note: For Right Jamb and Left Jamb modes there are 12 quick access presets available. For Head and

Stop modes there are 24 quick access presets available. To access presets 13 to 24 in Head and Stopmodes, press Next Page.

Note: See “Preset Screen” on page 31. for a detailed description of this screen.

R-1 R-3

R-12R-11R-10R-9

R-8R-7R-6R-5

R-4R-298.250

Right4

50

78.250

78.250

78 + (1/4)

96.250 80.250

96.250 78.250 96.500 98.000

78.750 81.000 98.000 96.500

Presets

78.250

NextPage


Field

24 979-2

Presets

Direct Access preset selection

1.From the Quick Access screen press Next Page until you reach the screen labeled Preset or LengthSetting.

2.Use the Keypad to enter the desired preset.3.Press Download Preset.4.The “O.K. to Move” popup will appear. Hold the O.K. to move

button until the head is in position.5.The 979 is now ready for work.Note: See “Length / Preset Screens” on page 32. for a detailed description of this screen.

Keypad Display

Keypad

Decimal Fraction Modify Quantity Previous Menu

Entered Value2727

Quantity

50

15

Download Preset

979-2 25

Preset Storage

1.Turn the Set Up key switch to On. This switch is located on the main electrical cabinet.2.From the Main menu select the desired mode.3.Press Next Page until you reach the Length Only screen4.Press Store Menu5.Enter the desired length and preset number.6.Press Store Program.7.To store more presets go back to step 268.Press Previous Menu until you reach the Main Run Screen.9.On the Main Run screen press Refresh Text to make the new presets visible.10.Turn the Set Up key switch to Off.Note: See “Length Only Screen” on page 34. for a detailed description of this screen.

Keypad Display

Keypad

New Length

Store Program

New Preset

Decimal Fraction Previous Menu

21.41

4242

26 979-2

Presets

Manual Length Entry

1.From the Quick Access screen press Next Page until you reach the screen labeled Preset or LengthSetting.

2.Use the Keypad to enter the disired length.3.Press Download Length.4.The “O.K. to Move” popup will appear. Hold the O.K. to move

button until the head is in position.5.The 979 is now ready for work.Note: See “Length / Preset Screens” on page 32. for a detailed description of this screen.

Keypad Display

Keypad


Entered Value

Current ModeCurrent Preset

2727

Quantity

50

HEAD15

Download Length

979-2 27

28 979-2

Touch Screen Interface


The following is an overview of the touchscreen functions for basic machine operation.

OK TO MOVE

Any time the cut length is changed, the “OK to Move” popup appears. The “OK to Move” button must be pressed during the time the movable head is moving. This safety feature ensures the operator will be in a safe position at the touchscreen and not near the moving heads. If “Abort Move” is pressed the dis-play returns to the previous screen.

HOMING

82.013

Current Cut Length

979-2 29

Run Screen

TABLE 1.

Button or Group Description

Controller Status Displays current motion controller program step

Error Message Displays motion controller error message (if any).

Kerf Saws (Optional) Turns the Kerf Saw function ON or OFF.

Maintenance Moves to the Maintenance screen. See “Maintenance Screen” on page 67.

Servo Troubleshooting Moves to Servo Troubleshooting screen. See “Servo Trouble Shooting” on page 80.

Wide Jamb • OFF: For stock less than 3 ½ inches wide• ON: For stock wider than 3 ½ inches wideNOTE: Jamb width change also requires a mechanical adjustment. See “Mechanical Set-up” on page 22.

Refresh Text Updates the text for the current display.

Machine Data Moves to the Machine Data screen. See “Machine Data” on page 35.

Clamp Setup Turns off the saws to allow the user to safely set up the clamps. page 22\

Controller Status

Error Message(None shown)

Ready to run. No cut loaded

Machine Datapage 35

Wide Jambpage 22 & below

ServoTrouble shooting

page 80

Maintenancepage 67

Kerf Saws(Optional)

Preset Menuspage 31

Clamp Set uppage 36

Refresh Text

30 979-2


Preset Screen

TABLE 2.


Controller Status Displays the current status of the motion controller.

Error Message Displays motion controller error message (if any).

Screen Title Displays mode selected along with head angles Right Jamb 45 | 00, Left Jamb 00 | 45, Head 45 | 45 or Stop 00 | 00.

Present Length Displays the real time cut length.

Presets Displays preset name and length for presets 1 through 12 of the currently selected mode

Download Preset Used to download a selected preset.

How to Download a preset:1. Select a preset2. Modify if naysayer using the Keypad Length / Preset screen.To access the

the Keypad Length / Preset screen3. Press Download Preset to load the preset into the machine for use.

Clamp Setup Turns off the saws to allow the user to safely set up the clamps. page 22

Current Preset Displays the currently selected mode and preset

Next Page Moves to the Keypad Length / Preset screen. See page 32

Previous Menu Moves to the Main Run screen. See “Run Screen” on page 30.

Preset Quantity Displays the quantity saved in the currently selected preset.

Present Length (Fractional Displays the length saved in the currently selected preset in decimal format

Present Length (Decimal) Displays the length saved in the currently selected preset in fractional format.

R-1 R-3

R-12R-11R-10R-9

R-8R-7R-6R-5

R-4R-298.250

Right4

50

78.250

78.250

78 + (1/4)

96.250 80.250

96.250 78.250 96.500 98.000

78.750 81.000 98.000 96.500

Presets

Screen Title

Present Length Present length(Decimal) (Fractional)

Preset quantity

Present Length

Controller StatusError Message(None Shown)

DownloadPreset

CurrentPreset

78.250

PreviousMenu

NextPage


Clamp Setuppage 22

R-478.250

Preset NamePreset Length

979-2 31

Length / Preset Screens

TABLE 3.


Current Preset Displays the current preset.

Current mode Display the current mode (Head, Left, Right, Stop)

Store Menu Moves to the Store display. See page 34.

Entered Value Displays the value entered by the keypad after Enter is pressed.

Download Length Downloads the length shown in the Entered Value Field.

Download Preset Downloads the preset shown in the Entered Value Field. There are 99 presets available for each mode (Head, Left, Right, Stop)

Quantity Displays the current quantity.

Previous Menu Returns to the previously displayed screen.

Modify Quantity Used to modify the saved quantity by calling the Keypad Modify screen (page 33)

Fraction Used to call the Key Fractional screen (page 33) for entering numerical data in a frac-tional format.

Decimal Used to enter a decimal point into a keypad entered numeric value.

Keypad Used to enter a numeric value.

Keypad Display Displays keypad entered digits.

Keypad Display

Keypad


Store Menu

Entered Value

Current ModeCurrent Preset

2727

Quantity

50

HEAD15

Download Length

Download Preset

32 979-2


Keypad Fractional Screen

This screen is used to enter fractional information in fractional format. When a key is pressed the value is displayed is shown in thirty seconds of an inch. For example if 1/4 is pressed, 08/32 will be displayed. When the correct value has been entered press previous menu to return to the previous screen.

Keypad Quantity Screen

This screen is used to change the number of parts to be processed. Enter the desired number using the keypad then press Close Menu to return to the previous screen.

(08/32)

Keypad

979-2 33

Length Only Screen

TABLE 4.


New Length Displays the length entered by the keypad after Enter for Length is pressed.

New Preset Displays the length entered by the keypad after Enter for Preset is pressed.

Store Program Used to store a new preset. To enable this function the Key Switch labeled ‘Set Up’ located on the main electrical box must be in the ON position.

Previous Menu Returns to the previously displayed screen.

Fraction Used to call the Key Fractional screen (page 33) for entering a length in fractional for-mat.

Decimal Used to enter a decimal point into a keypad entered length.

Keypad Used to enter a length.

Keypad Display Displays the length entered from the keypad.

Keypad Display

Keypad

New Length

Decimal Fraction

Store Program

Previous Menu

New Preset

21.41

4242

34 979-2


Machine Data

TABLE 5.


Machine Total Total number of boards run through the machine.

Daily Total Number of boards run throught the machine since Reset Daily was pressed.

Reset Daily Sets the Daily Total to 0.

Previous Menu Returns to the previously displayed menu.

Previous MenuReset Daily

Daily Total

Machine Total

979-2 35

Clamp Setup

Pressing the Clamp Setup button on either the Run screen (“Run Screen” on page 30) or the Preset screen (“Preset Screen” on page 31) turns off the saws to allow for safe clamp set up (see “Mechanical Set-up” on page 22). After the clamps are set use the screens shown above to re-start the saws.

Ready to run. No cut loaded

36 979-2

979-2 37

CHAPTER 3 Calibration

1.Go to the Main menu.2.Select the desired preset, modify if necessary.

NOTE: Set the quantity to greater than 50.3.Insert one board into the machine.

4.Press the “Start Sequence” foot pedal five times. This will run the one test board through the full pro-cess.

5.Measure the actual cut length of the test board.NOTE: If one of the cuts is at a 45-degree angle, measure the shorter dimension.

6.Compare the actual cut length to the preset cut length.• If the actual and preset cut lengths are the same, calibration is complete; skip the rest of this process.

7.From the preset screen, select “Maintenance”.8.From the Maintenance screen select “Calibration”.9.From the calibration screen, select the appropriate calibration type.

• Current cut angles: This calibration affects all presets with the currently selected cutting angles. Inthe following example, the calibration would affect all 45-degree and 0-degree cuts. Use this calibra-tion if a test cut is incorrect during standard production.

• Global: This calibration affects all presets. Use this calibration after mechanical changes to themachine, such as after replacing a saw blade.

10. Input the actual cut length from step 6.NOTE: Use “Back Space” or “Clear” to cor-rect typographical errors.

11.Press ENTER.12.The actual cut length should appear in the

“New Value” box.13.If the new value is correct, press “Confirm

Calibration”; if the new value is incorrect go back to step 10.NOTE: To reduce waste, use the same board used in step 4. Simply modify the cut length to app. 2 inches shorter.

14.Press “Close Menu”.15.Make confirmation cut by going back to step 3.

Actual Cut Length

Calibration

38 979-2

NOTE: To reduce waste, use the same board used in step 4. Simply modify the cut length to app. 2 inches shorter.A note on calibration: A 979-2 properly calibrated and mechanically set up will accurately make cuts within 1/1000” tolerance. Cut length accuracy is more dependant on material quality than the 979-2. On longer stock where bowing is an issue, use the center support to reduce this problem.

CHAPTER 4 Maintenance

This chapter describes how to maintain the 979-2 system. This chapter contains the following informa-tion:

• Maintenance schedule.......................page 40• Lubrication requirements...................page 42

979-2 39

Maintenance

Maintenance ScheduleKval recommends the following maintenance schedule to ensure proper machine operability.

Daily

• Blow off dust from the entire machine.• Lubricate linear bearings and chrome shaft with silicone (see lubrication requirements on).• Wipe down the machine with a clean dry cloth.• Check tooling for wear.• Wipe off the photo eyes with a clean dry cloth, and check to ensure that all fastening nuts are snug.

CAUTION: Fastening nuts (as well as eyes) are plastic and threads can strip easily.

• Check the air pressure to make sure it is set at 100 psi.• Refill lubricator with an ISO 32 standard hydraulic oil (use KVAL part# SYSLUBEG).

Weekly

• Check the machine for smooth motion through a complete door cycle.• Clean linear bearings and chrome shaft with a clean dry cloth, then lubricate.• Check air pressure to the machine.• Adjust and lock flow controls.

• Check all air lines & electrical wiring for kinks or rubbing.

Fastening Nuts

Adjustment knob

Tightening nut

40 979-2

Maintenance Schedule

• Remove and blow out air condition filters. One on the main electrical panel and one on the operator’sstation: Visually inspect the system to check for any worn or broken parts.

• “Visually inspect the system to check for any worn or broken parts.

May and December Checkups

• Wash filter and lubricator bowls with soapy water.• Grease all bearings and tighten all bolts (see grease locations on illustrations,). Access to some grease

fittings is difficult and will require a special needle point grease tip (supplied with your system).• Clean and lubricate all slides and cylinder rods with dry silicone spray.• Tighten all bolts.

Lift up and pull bottom out. Remove screw and slide up

979-2 41

Maintenance

Lubrication RequirementsThis section describes the parts of the machine that require periodic lubrication, and specifies the lubri-cants. In addition, it explains how to maintain the lubrication systems on the machine.

Linear Bearings

If the bearing is equipped with a grease fitting, it should receive 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N Lube EP-2) every 30 days. Bearings without grease fittings have been pre-lubricated at the factory and do not require fur-ther lubrication.

Flange Bearing and Pillow Blocks

Use Dura-Lith grease: 1 gram every 60 days.

Approved Lubrication Products for Lubricators

Chevron AW Hydraulic Oil 32 – or KVAL P/N SYSLUBG or G-C lubricants light AW R&O or Mobile DTE 24 or Shell Tellus32 or Gulf Harmony 32.

Gear Motor Lubrication Requirements

Oil change is recommended after 2000 hours or six months of operation. Use AGMA #8 gear lube or MOBILUBE HD 80 W-90 or equivalent

Ball Screws

Most CNC machines are equipped with ball screws. All ball screws should be lubricated Dura-Lith Grease (KVAL P/N Lube EP-2) for every 80 hours of operation. At each lubrication grease should be pumped into the fitting until clean grease comes out around the ball screw.

Ball screw lubrication points.

Ball NutBall Screw

EndBearing

EndBearing

42 979-2

Lubrication Requirements

Adjusting the Air Line Lubricator (not available on all machines)

Using the knob on the top of the lubricator, adjust until one drop per every other cycle is used (as observed through sight glass.)

Priming the Air Line LubricatorNew and used machinery run out of oil from time to time. It is a good practice to check your machine lubricator to insure that it is putting the proper dose of oil in the air lines. Usually 1 drop of oil every other cycle is a good rule of thumb. To prime the lubricator, find an air line on the carriage section of the machine that is energized, and dis-connect it, allowing the air stream to bleed air pressure away from any persons. Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose. Repeat this same pro-cedure for the back section and other trouble areas.Check the lines every week to two weeks.

NOTE: The Lubricator is not installed on all machines.

(Sight glass). Drop will form at end of cane shaped tube visi-ble inside glass.

(Adjustment knob). When the oiler has run dry, open the knob all the way until flow begins. Once you have a steady flow, tighten knob back down until you have one drop per every other cycle.

Lubricator

Regulator Filter

Set bottom valve to 90 psi

Set top valve to 100psiSight Glass. Check rate: 1 drop for ever two door cycles.

Adjustment Knob

979-2 43

Maintenance

Grease Points

Main Frame Bottom View

Bottom View

44 979-2

Lubrication Requirements

Fixed Head

979-2 45

Maintenance

Movable Head

Bottom View

46 979-2

Cut Depth Set-up

Cut Depth Set-upAdjusting the Saw Height

Lock and tag-out the machine before making any adjustments to the saw carriage. Refer to the “Safety First” section of this manual for further information on lock and tag-out procedures.The 979-2 saw travel is controlled at two points within the saw carriage: the mounting plate and the limit switch. To adjust the saw's travel you will have to adjust both.1.Lock and tag-out the 979-2.2.Remove the saw carriage guard.3.Remove the saw travel limit switch actuator mounting plate.4.Loosen the two bolts securing the saw mounting plate.5.Raise or lower the saw position as necessary.6.Re-tighten the saw mounting plate bolts.7.Re-install the saw travel limit switch actuator mounting plate.8.Adjust the saw travel limit switch actuator adjusting screw (if necessary) in or out, until the saw trav-

els properly.

Note:Adjust the saws' travel, keeping in mind that if the saws are raised too much, the saw may not lower enough to completely cut through particularly wide trim pieces.9.Replace the saw carriage guard(s).10.Un-lock machine and sign off tag.

979-2 47

48 979-2

Cut Depth Set-up

979-2 49

50 979-2

Cut Depth Set-up

979-2 51

52 979-2

Feed Cylinder replacement and Feed Dog Adjustment procedure

Feed Cylinder replacement and Feed Dog Adjustment procedure1.Turn off machine’s electrical power and compressed air.1.Remove the inside covers.l

2.Manually Pull both movable and fixed head dog plates against the Feed Forward stops

3.Replace the Feed Cylinder Feed Cylinder.4.Adjust the new Feed Cylinder placement to insure Feed Dog Plate has smooth travel for the full range

of motion.5.Tighten the Feed Cylinder lock nuts.

Feed Forward Stop

Feed CylinderFeed Dog Plate Feed Reverse Stop

979-2 53

6. Feed Dog Alignment:Note: Normally this adjustment would not be necessary. It is provided here for the rare occasion when adjustment is necessary.

Holding the right angle of a T-Square against the Fixed Head Dog plate, adjust the forward feed stops so both the fixed head middle feed dog and movable head feed dog and the alignment mark all line up.

Movable HeadFeed Middle Dog

Fixed Head Fixed Head T SquareMiddle Feed Dog Plate

Movable HeadPlate

Fixed Head

Fixed Head Forward Feed Stop Movable Head Forward Feed Stop

Fixed Head Dog Plate Movable Head Dog Plate

AlignmentMark

54 979-2

Feed Cylinder replacement and Feed Dog Adjustment procedure

7.Manually Pull both movable and fixed head dog plates agents the Feed Reverse stops8.Adjust the Feed Reverse stop for a gap of 8 15/16” between the forward edge of both Feed Dog Plates

and the Feed Forward Stop.

9.Reinstall the inside covers.

Feed Forward Stop

Feed Dog Plate Feed Reverse Stop

8 15/16”

979-2 55

56 979-2

CHAPTER 5 Troubleshooting

979-2 57

Troubleshooting

Troubleshooting the Air CylindersMost cylinders have an extend and retract port. To adjust the extend motion of a cylinder you must adjust the flow control on the retract port; this regulates the air flow exhausting from the cylinder and the opposite is true for the retract motion. 1.Check the air pressure to the machine.2.Check the flow controls to see that they are adjusted correctly and to the proper specifications.

3.Check for any obstructions to the cylinders such as screws or a mis-placed tool etc. FOLLOW ALL SAFETY GUIDELINES ANDSIGNS DURING THIS PROCESS.

4.Check the solenoid air valves:a.The solenoid valves can be manually operated by pushingthe red manual override button on the end of the valve.

b.If the valve seems to be leaking, the seals may be dry or contaminated with water or it maybethat the cylinder “O” rings are damaged and air is passing from one side to the other side of the cylinder which means the air is exhausting through the solenoid valve. It maybe is necessary to purchase a rebuild kit or a new cylinder.c.If the valve is not receiving an electrical signal, for instructions. It might be necessary to callin a specialist or check with KVAL customer service at 1-800-553-5825.

5.If an Air Leak is coming from an exhaust port on the solenoid air bank:

Manual over-ride button

CAUTION: Once activated, The valve will allow full pressure to cylinder. Make sure you are clear of all moving parts.

58 979-2

Troubleshooting the Air Cylinders

a.Check the solenoid for the manual override. If the solenoid has a manual override you canpush each of the buttons one at a time. When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty.

Adjusting Cylinder Extension Speed:

Adjusting Cylinder Retraction Speed:

979-2 59

Troubleshooting

Troubleshooting Electrical Problems

The electrical component systems are designed to expedite the troubleshooting process and minimize “down time”. In general, component systems have the input or feed functions at the top. Output or load functions are positioned at the bottom. Most two-voltage electrical panels are designed with the LOW VOLTAGES on the LEFT, and the HIGH VOLTAGES on the RIGHT. The majority of the system com-ponents are labeled with numbers that correspond with the electrical prints included in the electrical box door.Computer controlled machines have signals on the computer that light up when the input or output func-tions are energized, respectively. Computer controlled as well as non-computer controlled machines have white 120V control power terminal strips. This will indicate power supply from the respective cir-cuits. Idec controllers also have lights on them for the input and output functions. You can easily find out which circuits are failing by watching the lights turn on or off. Compare the lights on the IDEC control-ler to the electrical print to determine what systems are being affected.

If the Power Stops During Normal Operation

1.Check that the input power disconnect switch is not turned off.2.Check that all of the emergency stop buttons are in the normal position.3.Lock Out and Tag Out the main power source.4.Turn the panel disconnect switch in the off position, open the electrical panel door.5.Observe the disconnect switches. Look for loose or broken wires at the disconnect then at all of the

components.6.Check for continuity of all fuses with an OHM meter.7.Check motor overloads by pressing each white button (usually at the bottom of the panel) in

SEQUENCE,. If one is tripped there will be a slight resistance to touch and a “click” sound as it isreset.

WARNINGThe following checks require the electrical panel to be energized. These troubleshooting checks MUST BE PERFORMED BY A QUALIFIED ELECTRICAL TECHNICIAN.

1.Remove lock and tag outs on the main power sources.2.Manually close disconnect switches and energize the control circuit or transformer with its respective

switch. Observe that the numbers 1, 3 & 4 are lit on the white lighted terminal strip. This tells you thatthere are no overloads or emergency stops tripped.

3.Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain,non tripped limit switches, etc.) The most common failure is an improperly adjusted limit switch. Tocheck a limit switch, manually operate the limit switch. If the computer terminal strips lights, theswitch needs to be re-adjusted. For more information on the limit switch specifications, see the manu-facturer’s information. For limit switch adjustment procedures, refer to.

4.If a solenoid valve is suspected, and not cleared in the air checks section (see), it can be electricallyjumped to check operation.

THE FOLLOWING SHOULD ONLY BE ATTEMPTED BY TRAINED ELECTRICAL PERSONNEL.

60 979-2


Troubleshooting with the Status Light Panel

The Status List Panel is located on the front of the Operator’s Station, below the work surface area. It has six lights that are all illuminated when the system is in proper working order. If one or more lights are OFF, follow the process below to ascertain the cause.

NOTE: Be sure to proceed down the table, starting with the CONTROL POWER light.

CONTROL POWER

OVERLOAD RELAY

E-STOP

STOP

START

24VDC

979-2 61

Troubleshooting

Light If ON: If OFF:CONTROL POWER

Go to OVER-LOAD RELAY

• Check to see if the Control Transformer button is pulledout.• Is the Disconnect switch on the main electrical cabinet setto ON?• Is there 208, 220, 440, or 575 VAC to the top side of the Con-trol Transformer (E3)? If not, check the fuses at the Fuse Block (E5), and the contacts on the Control Transformer but-ton on the switch panel.• Is there 110 VAC between #1 & #2 on the110 VAC TerminalStrip? If not, check the fuse on the output side of the Control Transformer. If fuse is good, check power coming out of Control Transformer. If no power on the output side, and there is power going into the top of the Control Transformer, replace the Control Transformer. If there is power at the Con-trol Transformer, check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Ter-minal Strip.

OVERLOAD RELAY

Go to E-STOP

• There is No over-load relay on this machine. If there ispower to the Status Light panel this light will be lit.

E-STOP Go to STOP • Check to see the E-Stop button(s) is pulled out.

NOTE: Location and quantity of E-Stop buttons varies depending on customer need. Typical locations for E-Stop buttons are near the Rear Access Gate and near the Tool Changer Access Gate• For Single E-Stop button machines: Check for 110 VACbetween #2 and #4. If no voltage, check to see if the E-Stop button is pulled out. If the E-Stop button is pulled out and E-Stop light is OFF check the wiring. If no fault is found in the wiring turn off the DL-NCB main power and check for conti-nuity across the pulled out E-Stop switch.• For multiple E-Stop Button machines: With on side of themeter on #2 check for 110 VAC on #4 through #5. If at any point no voltage is found trace the wires to find the associ-ated E-Stop button and check to see if that button is pulled out. If the E-Stop button is pulled out and the E-Stop light is OFF check the wiring. If no fault is found in the wiring turn off the DL-NCB main power and check for continuity across the pulled out E-Stop switch.• Check to see if the Back Gate is closed.• Check to see if the Disconnect switch on the high-fre-quency electrical cabinet is ON.• Check for 110 VAC between #2 and #3A on the 110 VAC Ter-minal Strip. If there is 110VAC, go to next step: If the Discon-nect switch on the high-frequency electrical cabinet is OFF (closed) and there is not 110 VAC between #2 and 3A, check the wiring.• Check for 110 VAC between #2 and #3B. If there is 110 VAC,go to next step: If the contact on the Rear Access Gate is closed and there is no power between #2 and #3B, check for wiring problems.

62 979-2


STOP Go to START • Check for 110 VAC between #2 and #6. If there is voltage,press the Start button. If no voltage, check the Stop button to make sure it is all the way out and not stuck in, then check the contact to make sure it is closed. If still no voltage, check the wiring.

START Go to 24VDC • Push the Start button. If the Start light remains unlit, pushin the Start button and hold it in while a second person checks for voltage between #2 and #7. If there is 110 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wiring.

24VDC Home the 979-2 (see)

Check between DC+ and DC- for 24VDC. If no DC voltage, disconnect the + Brown/Red and - Blue/Black wires from the 24VDC power supply and check for DC voltage where those wires were disconnected.

If no voltage: • Check the input side for 110 VAC. If no 110 VAC, check thefuse. If there is 110 VAC and no 24VDC, replace the 24VDC Power Supply.

If there is 24VDC:• Reconnect the + Brown/Red and - Blue/Black wires to the24VDC power supply. • Trace the + Brown/Red wire to the DC terminal block.• Disconnect all brown wires from the + DC from the DC ter-minal block except the + Brown/Red wire form the + 24VDC power supply. • Check for +24VDC at between any –DC and +DC terminalon the DC Terminal block. • Reinstall the + brown wires one by one checking for+24VDC after installing each + brown wire. If at any point no voltage is found trace the last reinstalled wire and check for shorts.

979-2 63

Troubleshooting

Adjusting Limit Switches

If a machine suddenly stops in mid cycle, check the limit switches. A worn limit switch arm or a misadjusted limit switch is more than likely the cause. (Another potential cause is faulty photo eyes – for details.)Depending on the model of limit switch on your machine, the pre-travel (amount of movement from the limit switch arm’s resting position to the position at which the switch actuates – with a “click”) is either 5 or 20 degrees. The DL-NCB has five limit switches that have 5 degrees of pre-travel (3 on the X axis and 2 on the Y axis), and two switches that have 20 degrees of pre-travel (on the Cutter head). If the arm is moved to the full extent of its travel and you do not hear the limit switch “click”, the switch needs to be adjusted. Use the set screw on the limit switch arm and adjust the arm to activate at the desired degree of rotation (see illustrations below).

Examples of Limit Switches:

64 979-2

Troubleshooting Photo Detectors

Troubleshooting Photo DetectorsAnother cause of improper machine operation is a faulty or dirty photo detector.There are two types of photo detectors, Through Beams and Photo Eyes.

• Through Beam Detectors consist of an emitter and detector. The emitter sends a light beam that issensed by the detector. The detector then sends 0VDC to the PLC. If the beam is broken the detector sends 24VDC to the PLC.

• Photo Eye Detectors contain both emitter and receiver. If an object is within the Photo Eye’s sensingfield light from the emitter is reflected from the object back to the receiver. The Photo Eye then sends 24VDC to PLC. If no object is sensed the Photo Eye sends a 0VDC to the PLC.

If the photo detector is dirty, it will falsely sense the presence of a door, or other obstruction, and stop the machine operation. If a suspected Photo Detector is clean check for the proper DC Voltage.

979-2 65

Troubleshooting

Getting Help from KvalBefore you seek help, first try the troubleshooting procedures in.If you are still not able to resolve the problem, contact our customer support engineers:

• In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485• Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485• Email address is [email protected]

Technical Support business hours are 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Fri-day.

Product Return Procedure

If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure below to return the machine or part.Note: Non-Warranty returns are subject to a 15% restocking charge.1.Obtain the packing slip and/or invoice numbers of the defective unit, and secure a purchase order

number to cover repair costs in the event the unit is determined to be out of warranty.2.Reason for return: Before you return the unit, have someone from your organization with a technical

understanding of the 979-2 system and its application include answers to the following questions:• What is the extent of the failure/reason for return? What are the relevant error messages or error

codes?• How long did it operate?• Did any other items fail at the same time?• What was happening when the unit failed (e.g., installing the unit, cycling power, starting other

equipment, etc.)?• How was the product configured (in detail)?• Which, if any, cables were modified and how?• With what equipment is the unit interfaced?• What was the application?• What was the system environment (temperature, spacing, contaminants, etc.)?

3.Call Kval customer support for a Return Material Authorization (RMA). When you call:• Have the packing slip or invoice numbers available.• Have the documented reason for return available.

4.Send the merchandise back to Kval.• Make sure the item(s) you are returning are securely packaged and well protected from shipping

damage• Include the packing slip or invoice numbers.• Include the documented reason for return.• Include the RMA number with the parts package.

66 979-2

Touch Screen Troubleshooting

Touch Screen TroubleshootingMaintenance Screen

For information of each of the screens listed in the Maintenance menu refers to the page listed between the arrows:

See page __

M A I N T E N C EMACHINESTATUS

See page 68

SEQUENCE DOES NOTCOMPLETE See page 69

START SEQUENCE(FEED)

See page 70

SAWS DO NOTEXTEND

See page 71

PLC INPUT-BITSTATUS

See page 74

GALIL I/OSTATUS

See page 77

SAWS DO NOTSTART

See page 72

PLC OUTPUT-BITSTATUS

See page 75

KERF SAWSEQUENCE See page 78

HEADS DO NOTADJUST

See page 73

PLC M-BITSTATUS

See page 76

TECH.SUPPORT

See page 79

CALIBRATION See page 37

MACHINESENORS

See page 85

PREVIOUSMENU

See page 68

979-2 67

Machine Status

TABLE 6.

Title Notes

Motor Stop Q-2 Motor MTR2. See “Right or Movable Head” on page 86. for location.

LS Left UP I-06 Limit switch: See “Left or Fixed Head” on page 87. for location.

LS RIght UP I-07 Limit switch: See “Right or Movable Head” on page 86. for location.

LS Right Extend I-35 Limit switch: See “Right or Movable Head” on page 86. for location.

LS Left Extend I-34 Limit switch: See “Left or Fixed Head” on page 87. for location.

Right Extend M-60 Internal PLC register, requires PC to PLC interface and WindLDR program.

Left Extend M61 Internal PLC register, requires PC to PLC interface and WindLDR program.

Right Cyl.Ext, Off Q-35 Cylinder: See “Right or Movable Head” on page 86. for location.

Left Cyl. Ext. Off Q-34 Cylinder: See “Left or Fixed Head” on page 87. for location.

Left 0 Deg. (M-334) Internal PLC register, requires PC to PLC interface and WindLDR program.

LS Left 0-Deg. Pos. (I-01) Limit switch: See “Heads - Bottom View” on page 88. for location.

Right 0-Deg. (M-335) Internal PLC register, requires PC to PLC interface and WindLDR program.

LS Right 0-Deg. Pos. (I-02) Limit switch: See “Heads - Bottom View” on page 88. for location.

Retracted I-10 Limit switch: See “Heads - Bottom View” on page 88. for location.

Extended I-11 Limit switch: See “Heads - Bottom View” on page 88. for location.

68 979-2


Sequence does not complete

TABLE 7.

Title Notes

Left Cut Started (M-35) Internal PLC register, requires PC to PLC interface and WindLDR program.

LS Left Saw up (I-06) Limit switch: See “Left or Fixed Head” on page 87. for location.

Right Cut Started (M-36) Internal PLC register, requires PC to PLC interface and WindLDR program.

LS Right Saw UP (I-07) Limit switch: See “Right or Movable Head” on page 86. for location.

LS Feed retracted (I-10) Limit switch: See “Heads - Bottom View” on page 88. for location.

Saw Motors Retracted (M-20) Internal PLC register, requires PC to PLC interface and WindLDR program.

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Start Sequence (Feed)

TABLE 8.

Title Notes

OK to FEED (M-22) Internal PLC register, requires PC to PLC interface and WindLDR program.

Miter Stop OFF (M-333) Internal PLC register, requires PC to PLC interface and WindLDR program.

PE Board Straight #1 (I-12) Photo Eye: See “Left or Fixed Head” on page 87. for location.

PE Board Straight #2 (I-13) Photo Eye: See “Right or Movable Head” on page 86. for location.

Straight (T-11) Internal PLC timer, requires PC to PLC interface and WindLDR program.

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Saws do not extend

TABLE 9.

Title Notes

Setup Off (M-290) Internal PLC register, requires PC to PLC interface and WindLDR program.

Delay Clamp On (T-08) Internal PLC timer, requires PC to PLC interface and WindLDR program.

Delay Start Saws (T-09) Internal PLC timer, requires PC to PLC interface and WindLDR program.

Start Saw Cyl Extended (M-33) Internal PLC register, requires PC to PLC interface and WindLDR program.



Right Cut Started (M-36) Internal PLC register, requires PC to PLC interface and WindLDR program.

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Saws do not start

TABLE 10.

Title Notes

LS Left Saw Not Up Pos. (I-06) Limit switch: See “Left or Fixed Head” on page 87. for location.

LS Right Saw Not Up Pos (I-07) Limit switch: See “Right or Movable Head” on page 86. for location.

Left Kerf Retracted (I-14) Underneath left head at retracted end of Kerf saw travel, no picture available.

Right Kerf Retracted (I-15) Underneath right head at retracted end of Kerf saw travel, no picture available.

Setup Mode (M-290) Internal PLC register, requires PC to PLC interface and WindLDR program.

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Heads do not adjust

TABLE 11.

Title Notes

LS Left Saw Not Up Pos. (I-06) Limit switch: See “Left or Fixed Head” on page 87. for location.

LS Right Saw Not Up Pos (I-07) Limit switch: See “Right or Movable Head” on page 86. for location.

Left Kerf Retracted (I-14) Underneath left head at retracted end of Kerf saw travel, no picture available.

Right Kerf Retracted (I-15) Underneath right head at retracted end of Kerf saw travel, no picture available.

OK to Move Heads (M-290) Internal PLC register, requires PC to PLC interface and WindLDR program.

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PLC Input-Bit Status

TABLE 12.

Title Notes

I-00 ## Not used

I-01 Left Head @ 45-DEG Limit switch: See “Heads - Bottom View” on page 88. for location.

I-02 Right Head @ 45-DEG Limit switch: See “Heads - Bottom View” on page 88. for location.

I-03 ## Not used

I-04 Start Sequence Foot Switch, no picture available.

I-05 ## Not used

I06 Left Saw UP Limit switch: See “Left or Fixed Head” on page 87. for location.

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PLC Output-Bit Status

TABLE 13.

Title Notes

Q-00 Left Kerf Saw Kerf saw motors on both left and right head. No picture available.

Q-01 Right Kerf Saw Limit switch: See “Heads - Bottom View” on page 88. for location.

Q-03 Not used

Q-04 Eye Blow Off Blow off for photo eyes on both left and right heads. See page 87 and page 86.

Q-05 Clamp Clamps on both left and right heads. No picture available.

Q-6 Feed Cylinder Cylinder to power feed an both left and right heads. No picture available.

979-2 75

PLC M-Bit Status

All M-Bits are internal PLC registers. Viewing requires PC to PLC interface and WindLDR program.

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GALIL IO Status

TABLE 14.

Title Notes

PLC:I-40,GALIL:0-01 GALIL OUT #1 (Servo Request to move)

PLC:I-41,GALIL:0-02 GALIL OUT #2 (45 -45)

PLC:I-42,GALIL:0-03 GALIL OUT #3 (0 - 0)



PLC:I-45,GALIL:0-06 GALIL OUT #6 (In Position)

PLC:I-46,GALIL:0-07 GALIL OUT #7 (Quant = 0 & In Position)

PLC:I-47,GALIL:0-08 GALIL OUT #8 (Homed)

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Kerf Saw Sequence (optional)

TABLE 15.

Title Notes

Left 45-DEG (I-01) Limit switch: See “Right or Movable Head” on page 86. for location.

Motor Start Q-00 Left Kerf saw motor located under left head. No picture available.

Cylinder Down Q-07 Cylinder to move left Kerf saw. No picture available.

Right 45-DEG (I-02) Limit switch: See “Right or Movable Head” on page 86. for location.

Motor Start Q-01 Right Kerf saw motor located under left head. No picture available.

Cylinder Down Q-010 Cylinder to move right Kerf saw. No picture available.

Saw Motors Retracted (M-20) Internal PLC register, requires PC to PLC interface and WindLDR program.

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Technical Support

Contact information.

979-2 79

Servo Trouble Shooting

Both the “Motor & Thread” and “I/O & Error Log” buttons call screens that display the present motion control system status. This information may be required by a service technician during troubleshooting.

Limit - Switch Timing See page 81

SET Minimum cut See page 83

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Limit - Switch Timing

General process description:

Note: Most KVAL machines automate this process, see “979-2 X Axis Limit Switch Timing” on page 82 for machine specific instructions. Limit Switch Timing sets the home position of an axis in relation to the Index marker pulse generated by the CNC motor. Ideally the index marker pulse should be one half a motor rotation away from the home limit switch activation point. This is accomplished by: 1.Moving the axis to the home limit activation point 2.Backing away form the home limit switch until the home limit is deactivated3.Rotating the motor until the index marker pulse is generated.4.Measuring the amount of motor rotation. If the rotation is between.4 and.6 the homing process is com-

plete.5.If the amount of motor rotation is less than.4 or grater than .6 the limit switch activator bolt needs

adjustment. If adjustment is necessary, put wrenches on both the limit switch activator bolt and the limit switch lock bolt, then loosen the lock bolt. The limit switch activator bolt is now free for adjust-ment. Adjustment should be made in small increments, best practice being two or three bolt flats at a time.• If the motor rotation is less the .4* turn the limit switch activator bolt clockwise, increasing the motor

rotation distance.• If the motor rotation is grater than .6* turn the limit switch activator bolt counter clockwise, decreas-

ing the motor rotation distance.6.Tighten the limit switch lock bolt using the two wrench method mentioned in step 81*1 = one full motor rotation.

Index MarkerPulse

Home Limit

Ball Screw

CNC Motor

Belt

Pulleys

The distance of

motor rotation.

Ball Nut

approximately one half

Axis

Limit Switch activator Bolt

Home Position

Limit SwitchLock Bolt

Home Limit SwitchActivation Point

(Must be 5ºSwitch

travel)

Note: The Home Limit Switch and /or Limit Switch Activator Bolt is painted orange on some models.

979-2 81

979-2 X Axis Limit Switch Timing

1.From the main run screen press Servo Troubleshooting.2.Press Limit Switch Timing.3.The O.K> to move screen will appear. Press the O.K to

move button to allow the machine to run the limit switch timing routine.The movable head will travel away from the fixed head and stop at the far end of the machine. It will them move slowly toward the fixed head and stop.

4.If “Passed” appears at the top of the Servo trouble shooting the process is complete. If “Failed” appears at the top of the servo trouble shooting screen a second message will appear giving instructions on how to adjust the home limit switch activation bolt. Follow the instructions, then go back to step 2.See the illustration below for adjustment locations

Home LimitSwitch

Limit Switch activator Bolt

Limit SwitchLock Bolt

82 979-2


Set Minimum Cut

This process sets the minimum cut length.1.From the main run screen press Servo Troubleshooting.2.Press Set Minimum Cut.3.The O.K> to move screen will appear. Press the O.K to

move button to allow the machine to run the Set Mini-mum Cut routine.The movable head will travel toward the fixed head and stop. The minimum cut distances will appear at the top of the servo trouble shooting screen.

979-2 83

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Part Locations

Part LocationsGeneral Top View

Control TransformerButton

Left or Fixed Head

Right or Movable Head

Start MachineButton

E-StopButton

E-Stop Button

979-2 85

Right or Movable Head

KeyDescription

Motor MTR2:Right SawMC-2 (Q2)

Blow OffOutput

Q4

Photo Eye:Board #2 Straight

PE-13 (I13)

E-Stop ButtonControl Circuit #3

Limit Switch: Right Saw Retracted

LS-7 (I07)

Limit SwitchRight Saw Extended

LS-35 (I35)

SV-25 Cylinder:

Extended (Q35) (Port B)Retracted (Q35) (Port A)

Control ValveExtend Right Saw

SV-35 (Q35)

Right Saw Extended*

*Retracting the Right Saw Extend cylinder will cause the Right Saw to drop. Extending this cylinder will cause the Right Saw to rise.

Machine Sensor locations Touch Screen

PLC Output labelTouch Screen Label (PLC port)

86 979-2

Part Locations

Left or Fixed Head

Limit SwitchLeft Saw Retracted

LS-6 (I06)

Limit SwitchLeft Saw Extended

LS-34 (I34)

SV-34 Cylinder: Left Saw Extended*

Extended (Q34) (Port B)Retracted (Q34) (Port A)

Control ValveExtend Left Saw

SV-34 (Q34)

*Retracting the Left Saw Extend cylinder will cause the Left Saw to drop. Extending this cylinder will cause the Left Saw to rise.

Motor MTR1Left Saw

MC-2 (Q2)

Photo EyeBoard #1 Straight

PE-12 (I12)

Blow OffQ4

KeyDescription



979-2 87

Heads - Bottom View

Cylinder: Left Saw 45ºExtend Q31Retract Q30

Limit SwitchLeft Saw 45º

I01

Limit SwitchFeed Retracted

I10

Limit SwitchFeed Forward

I11

Bottom View

Left Head

Right Head

Cylinder: Left Saw 45ºExtend Q32Retract Q33

Limit SwitchLeft Saw 45º

I02

KeyDescription



88 979-2

Part Locations

Top View and Main Valve Bank

Limit Switch+Crash

Main Valve Bank

LS-50 (I50)

Limit Switch-Crash

LS-51 (I51)

Limit SwitchHome

LS-52 (I52)

Port A Port ABlow OffClamp

Feed Cylinder & counter

Port B Port B Left Saw 0º

Q31

Right Saw 45º Q32

Right Saw 0º Q33

Left Saw 45ºQ30

Q4Q5

Q6


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90 979-2

Warranty

WarrantyKVAL Inc. will repair or replace any unserviceable parts not covered by their own manufacturer's war-ranty when malfunction is caused by faulty manufacturing or design up to one year or 2080 production hours after the delivery date, whichever comes first. This warranty does not cover items that wear out during normal use, such as (but not limited to) tooling, chipout blocks, and screwdriver bits.This warranty does not cover parts that become damaged or unserviceable due to misuse or abuse of the machine as determined by material safety data information and maintenance recommendations in this owners' manual. Parts returned under warranty will be inspected by Kval to determine whether that part qualifies for repair or replacement as specified in this warranty.KVAL Inc. is not responsible for costs associated with downtime, lost orders, damage to customer's product or workpieces, or other costs not specifically covered in this warranty.When problems cannot reasonably be resolved via telephone support, we will send a technician to your facility. For machines with an existing Ethernet connection capability, cost of technician's visit will not be included under warranty unless a broadband connection has first been made to the machine.

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Aair supply (psi) 43Ccompliance with codes and regulations 3Ddoor sensors See photo detectorsEelectric eyes See photo detectorsHhelp 66Llimit switches, adjusting 64lock out procedure 4Pphoto detectors

troubleshooting 65power

disconnect switches 4lock out procedure 4troubleshooting 60

product return procedure 66proximity sensors See photo detectorsRreturn material authorization (RMA) 66returning the product to Kval 66Ssafety cage

guidelines for entering 3safety guidelines 3sensors See photo detectorsshutoff valve, air 43Ttag out guidelines 5technical support 66

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Documents

Innovation, Quality & Honesty 979-2 Miter Trim Saw System … · 2019-05-24 · 979-2 Innovation, Quality & Honesty 979-2 Miter Trim Saw System Reference Published: 4/24/07