Kval 965X User manual

Innovation, Quality & Honesty
Service Manual
Published: June 10, 2021
965X Jamb Machining System
With KvalCAM®
Service Manual 965-X System

KVAL 965-X Service Manual
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property of KVAL Inc., and is to be used solely by Customer as an operating manual
for KVAL Inc. machines. Neither this Manual nor any of the information contained
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written permission of KVAL Inc. For authorization to copy this information, please
call Kval Customer Support at [phone] or fax [phone]. Outside the
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Manual Part Number: DOC-228-1-SRV
965-X is a trademark of Kval Incorporated.
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Copyright 2021 Kval Incorporated. All rights reserved.
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rated products, contact the Customer Support Department
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K VA L 965-X Service Manual
KVAL 965-X Service Manual
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KVAL 965-X Service Manual

Table of Contents
965X Service Manual
Chapter 1 Introduction to the 965X
Chapter 1 at a Glance.............................................................. 1-1
Overview of the 956X System ................................................. 1-2
About this Manual.................................................................................1-4
Safety First!.............................................................................. 1-6
Safety Sheet Sign-Off Sheet.................................................................1-6
Safety Terminology of Labels................................................................1-6
Safety Guidelines..................................................................................1-6
Lockout-Tagout Guidelines ...................................................... 1-10
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-10
Lockout Tagout Procedure....................................................... 1-11
Pre-Steps Before Lockout Tagout.......................................................1-11
Lockout Tagout Power ........................................................................1-11
Lockout Tagout Air Supply ..................................................................1-12
Start Maintenance...............................................................................1-12
Post Maintenance Steps.....................................................................1-12
Zero-Energy to Start-Up .......................................................... 1-13
Getting Help from KVAL........................................................... 1-15
On-Line Help.......................................................................................1-16
How to Download the Service Application ............................... 1-17
Download Application .........................................................................1-17
Safety Sign-Off Sheet .............................................................. 1-20
A Note to the Operator........................................................................1-20
Chapter 2 System IT Administration
System IT Administration ......................................................... 2-2
About the 965X Line Computer ............................................................2-2
Connections on the PLC.......................................................................2-2
Chapter 3 Maintenance of the 965X
Maintenance Schedule ............................................................ 3-2
300 Cycle Maintenance Steps ................................................. 3-4
Clean, Clean, Clean!.............................................................................3-4
600 Cycle Maintenance Steps ................................................. 3-5
Check Air Gauges and Inspect Water Traps.........................................3-5
Inspect Tooling......................................................................................3-5

965X Service Manual
Table of Contents
Empty Dust Collection Units .................................................................3-6
3,000 Cycle Maintenance Steps .............................................. 3-7
I Inspect all Photo Eyes ........................................................................3-7
Inspect Limit Switches ..........................................................................3-7
Inspect Airlines......................................................................................3-7
Refill Lubricators...................................................................................3-8
Grease Ball Screw Bearings.................................................................3-8
Clean Bearing Shafts............................................................................3-8
12,000 Cycle Maintenance Steps............................................ 3-9
Inspect Air Cylinders .............................................................................3-9
Inspect Ball Rail Shafts and Ball Screws..............................................3-9
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts...........3-9
72,000 Cycle Maintenance Steps............................................ 3-10
Inspect Nuts and Bolts........................................................................3-10
Electrical .............................................................................................3-10
Computer Backup...............................................................................3-10
Wash Filter and Lubricator Bowls .......................................................3-10
Maintenance NO-GOES .......................................................... 3-11
Lubrication Schedule ............................................................... 3-12
Typical Lucubration Kit........................................................................3-12
Lubrication Requirements........................................................ 3-13
Pillow Block Bearing Housings ...........................................................3-13
Flange Bearing Housings ...................................................................3-14
Ball Rail Bearing .................................................................................3-14
About Taper Bearings .........................................................................3-15
Tapered Bearing Housings .................................................................3-15
Ball Screw Nut ....................................................................................3-16
Ball Screw Drive Assembly .................................................................3-16
How to Prepare the 965X for Greasing.................................... 3-17
Cutter Head Location After Park .........................................................3-17
Grease Locations for the 965X................................................ 3-18
Locations of Cutter Head Bearings.....................................................3-18
Locations of Bearings on Each Tool ...................................................3-19
Locations of Rail Bearings on the Clamp Assemblies ........................3-20
Description of Air Input System................................................ 3-22
Air Input with Lubrication ...................................................................3-22
Air Line Without Lubricator .................................................................3-23
Identifying 965X Tools.............................................................. 3-24
About the Tool Kit..................................................................... 3-25

Table of Contents
965X Service Manual
About the Tool Kit................................................................................3-25
How to Access to Bit Assemblies............................................. 3-26
Remove and Replace the Router or Pre-Drill Bits ................... 3-27
Check or Update Tool Configuration........................................ 3-29
About Chisels........................................................................... 3-30
Chisel Orientation on Machine............................................................3-30
Changing Chisels on a Machine .........................................................3-30
Replacing the Self Lubricator................................................... 3-32
Replace the Lubricator Well................................................................3-32
Process to Change an Auto-Lubricator...............................................3-33
Collet Torque Values................................................................ 3-34
Chapter 4 Troubleshooting the 965X Line
Get Live Technical Help ........................................................... 4-2
Troubleshooting Basics ........................................................... 4-3
Before you Adjust..................................................................................4-3
Analyze the Sub Systems.....................................................................4-5
About Motion Control ............................................................... 4-6
Sequencing...........................................................................................4-6
Point to Point ........................................................................................4-6
Incremental...........................................................................................4-6
Basic Control Circuit ................................................................ 4-7
About a Typical Contactor Control ........................................... 4-8
About Contactor Troubleshooting .........................................................4-9
About Typical VFD Motor Drive Control................................... 4-10
About the VFD ....................................................................................4-11
About VFD Troubleshooting................................................................4-12
About a Typical Pneumatic Circuit ........................................... 4-13
Typical Pneumatic Assembly ..............................................................4-14
About the Coil (Solenoid)....................................................................4-14
About Cylinder Operation ...................................................................4-15
How the Pneumatic System Works ....................................................4-15
Important Notice about Adjusting Cylinder Speed ..............................4-17
Adjusting Cylinder Extend Speed .......................................................4-18
Adjusting Cylinder Retraction Speed .................................................4-18
Valve Bank Locations .............................................................. 4-19
Location of Valve Banks on the 965X .................................................4-19

965X Service Manual
Table of Contents
Network System Overview....................................................... 4-20
Connections to Servo Drives ..............................................................4-20
965X Servo Motor Locations ..............................................................4-21
About Switches and Sensors................................................... 4-22
Using Sensors to Trouble Shoot .........................................................4-23
Sensor Locations on Machine ............................................................4-23
Frame Sensors ...................................................................................4-23
Cutter Head Sensors ..........................................................................4-24
Troubleshooting Electrical Problems ....................................... 4-25
If the Power Stops During Normal Operation .....................................4-25
Description of the Light Tower ................................................ 4-27

Chapter 1 at a Glance
1-1
965X Service Manual
CHAPTER 1 Introduction to the 965X
This chapter provides an overview of the KVAL 965X machine and important safety information to
follow when operating the machine.
Chapter 1 at a Glance
Section Name Summary Page
Overview of the 965X
System
This section provides an overview of the
machine. It includes a general description
and a table of available options
page 1-2
Safety First! IMPORTANT safety information is described
in this section
page 1-6
Lockout-Tagout Guidelines Procedures describing Lockout Tagout. page 1-10
Zero-Energy to Start-Up Procedure to power up your machine for the
first time.
page 1-13
Getting Help from KVAL This section describes the method to con-
tact the KVAL service center for help. The
section includes how to get information from
the specification plate tor provide to KVAL,
service center hours, and return procedures
page 1-17
Safety Sign-Off Sheet A record to track operators that are trained
on the machine.
page 1-20

Overview of the 956X System
1-2
965X Service Manual
Overview of the 956X System
The 965X processes hinge, strike and head jambs, as well as mull posts for door frames.Jamb Cut-
down functionality is reduced to jambs. With CNC functionality, the 956X allows the operator to
select hinge or lock locations on the jamb and route various types of hinge and latch-plate tem-
plates as well as pre-drill for hardware attachment. Four corner square chisels are standard for
ASA or T strike and hinge pocket squaring. The counter rotating routers can also be used to cut
jambs to length and rout angled sill gains in the jamb bottom. The 965X comes standard with four
(4) auto-chisels and three (3) hi-frequency routers, each adding unique functionality to the
machine.
CNC Functionality:
The 956X, a 3-Axis (x,y,z) CNC machine, provides the operator with the ability to dictate mortise
pattern, depth, radii, location, as well as pre-drill pattern and depth. Each variable is easily modi-
fied via our touch screen and KvalCAM program. Key components include Beckhoff® AC servo
motors, controller and industrial computer which in turn drive a gear and rack system for X-axis
and precision ball screws for Y/ Z axis router and chisel movements.
Programming:
KvalCAM is used create files for a wide variety of hardware templates and can also be used to pro-
gram end dados or cut material to length. KvalCAM offers increased supportability and trouble-
shooting capabilities. Newly developed error codes and code definitions quickly identify any
problems to the operator and or Kval support technician on-site or via a connection to our offices.

Overview of the 956X System
1-3
965X Service Manual
Calibration and Quality Control:
Two fixed end stops (left and right) are used for location index. These automatically retract when
end work is required next to the stop. Routers: The machine head includes two hi-frequency 3HP
spindle motors with double bearings, rotating in opposite directions. The counter-rotating spindles
are combined with tool path programming to eliminate chipping at the jamb edge. A third hi-fre-
quency 1.5HP spindle is utilized as a point-to-point pre-drill system for hardware application.
Chisels:
The 965X is equipped with four (4) chisels, mounted in pairs, for the square hinges for higher-end
markets
Safety:
An electronic zone sensor is included to prevent access to the machine while routers are turning or
the machine is moving. The backside of the machine is secured via metal fencing. purpose of
removing radii and providing near perfect square latch plates or

Overview of the 956X System
1-4
965X Service Manual
About this Manual
This manual is part of a package delivered with the machine line.
Integration Package includes the following:
Operation Manual includes the following:
Service Manual includes the following
Chapter Title Description
1Introduction Descriptions of Machine Line and
Safety Information.
2
Operation Inter-
face
Descriptions of how to power
machine line, and operator inter-
face user screens.
3Calibration Descriptions of Calibration Rou-
tines and how to use the interfaces
4Tour of 965X Identification and descriptions of
the 965X machine assemblies.
Chapter Title Description
1Introduction Safety Information.
2System IT Admin-
istration
Descriptions of the PLC system,
and computer system.
3Maintenance Maintenance steps for the
machine line
4Trouble Shooting Troubleshooting tips and theory of
operation.

Overview of the 956X System
1-5
965X Service Manual
KvalCAM Reference Manual
Chapter Title Description
1KvalCAM reference Description of the Interface
2KvalCAM Examples Examples of Common Door Job
Features
3KvalCAM Common
Term s
Common terms associated with
KvalCAM

Safety First!
1-6
965X Service Manual
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-20.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-
vide safety information to operators. Safety labels should be clearly visible to the operator and
must be replaced if missing, damaged, or illegible.
There are three types of warning labels or decals:
• DANGER means if the danger is not avoided, it will cause death or serious injury.
• WARNING means if the warning is not heeded, it can cause death or serious
injury.
• CAUTION means if the precaution is not taken, it may cause minor or moderate
injury.
Safety Guidelines
In addition to the caution and warning labels affixed to this machine, follow the guidelines below
to help ensure the safety of equipment and personnel.
This machine 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 dam-
age to equipment and/or serious injury to personnel.
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.
Training

Safety First!
1-7
965X Service Manual
Never operate the machine without proper eye and
ear protection.
Protective Gear
• Never reach hands beyond safety cage. Servo
motors can unexpectedly move quickly.
• Never clear screws or hinges out of the machine
while it is running.
• Never reach into the router area to retrieve a
hinge. The router may still be running down
after shut down.
• Never perform any maintenance unless machine
is at zero state.
• Never clean the machine while it is running.
• Never walk away from the machine while it is
running.
When the Machine is ON
The compressed air system connected to this
machine should have a three-way air valve
for shut-off and pressure relief.
All cylinders on machine are under high
pressure and can be very dangerous when
activated. Before performing any mainte-
nance or repairs on this machine turn off the
main air disconnect. Lockout and tagout
this connection.
See “Lockout Tagout Procedure” on
page 1-11.
Compressed Air

Safety First!
1-8
965X Service Manual
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
electrical power supplying this
machine.
When opening the cabinet you must first turn off the
disconnect switch. When the cabinet door is open there
is still power on the top side of the disconnect switch.
Some machines are powered by more than one supply
located at different locations. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
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 applicable state and/or federal
code requirements.
Before Conducting Maintenance
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the
manufacturers safety precautions.

Safety First!
1-9
965X Service Manual
KVAL 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 regula-
tions which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP pro-
duction. It is your responsibility to immediately protect
your employees against any such hazard.
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
regarding the safe operation of this machine
Follow Your Company’s Safety Procedures
In addition to these safety guidelines. Your company
should have on-site and machine specific safety proce-
dures to follow.

Lockout-Tagout Guidelines
1-10
965X Service Manual
Lockout-Tagout Guidelines
• Place a tag on all padlocks. On the tag, each
operator must put their own name and date.
(These locks are only to be removed by the
person who signs the tag)
• If more than one person is working on the
machine, each additional person places a lock
and tag on each disconnect.
• Only each operator may remove their own
lock and tag.
Important: 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 shutdown
R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)
O...... OFF! Shut off all power sources and isolating devices
P...... Place lock and tag
E...... ENERGY: Release stored energy to a zero-energy state
R ...... Recheck controls and test to ensure they are in the “OFF” state

Lockout Tagout Procedure
1-11
965X Service Manual
Lockout Tagout Procedure
This policy is required by OSHA regulation 1910.147 and Cal OSHA’S
SB198 ruling of July 1991.
Use the following lockout procedure to secure this machine while it is
powered down. During a lockout, you disconnect all power and shut
off the air supply. Be sure to use the tagout guidelines noted below.
Pre-Steps Before Lockout Tagout
Lockout Tagout Power
1. Evaluate the equipment to fully understand all energy sources (multiple electrical
supplies, air supply and 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. Turn off machine. See Chapter 2 for power down and power up procedures.
5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF
position. Then push the red tab to pop it out. Place a padlock through the hole.
Place your tag on the padlock, as per the tagout guidelines below. (see illustration
below).
Power
Note: When multiple people are working on the machine, each person needs to
have a lock on the handle in the extra holes provided.
Insert Lock into hole.
Turn Switch to the
OFF position
Lock and Tag out

Lockout Tagout Procedure
1-12
965X Service Manual
Lockout Tagout Air Supply
Start Maintenance
7. Once the locks and tags are in place and all personnel are clear, attempt to operate
the machine to ensure equipment will not operate.
8. Maintenance or repairs may started.
Post Maintenance Steps
9. After maintenance is completed, the person performing the work must ensure all
tools, spare parts, test equipment, etc., are completely removed and that all guards
and safety devices are installed.
10. Before removing the locks and tags, the person who attached them shall inspect the
equipment to ensure that the machine will not be put in an unsafe condition when
re-energized.
11. The lock and tag can now be removed (only by the person(s) who placed them),
and the machine can be re-energized.
12. The tags must be destroyed and the locks and keys returned to the lockout center.
6. Turn all air valves to the OFF position and place a pad-
lock through the hole (see illustration below).
NOTE: Place your tag on the padlock, as per the
tagout guidelines.