Kval 979-2 Operation manual

Innovation, Quality & Honesty
Operation and Service Manual
Published 5/24/2019
979-2 Miter Trim Saw System
979-2 Miter Trim Saw System

KVAL 979-2 Operation/Service Manual
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Manual Part Number: DOC-146_3-OPS
The 979-2 Miter Trim Saw System is a trademark of Kval Incorporated.
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KVAL 979-2 Operation/Service Manual
KVAL 979-2 Operation/Service Manual
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KVAL 979-2 Operation/Service Manual

KVAL 979-2 Operation / Service Manual
Chapter 1 Introduction to the 979-2 Miter Trim Saw System
Chapter 1 at a Glance.............................................................. 1-1
Overview of the 979-2 Miter Trim Saw System........................ 1-2
About this Manual .................................................................................1-3
Safety First!.............................................................................. 1-4
Safety Sheet Sign-Off Sheet.................................................................1-4
Safety Terminology of Labels................................................................1-4
Safety Guidelines..................................................................................1-4
Lockout-Tagout Guidelines ...................................................... 1-8
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-8
Lockout Tagout Procedure....................................................... 1-9
Pre-Steps Before Lockout Tagout .........................................................1-9
Lockout Tagout Power ..........................................................................1-9
Lockout Tagout Air Supply ..................................................................1-10
Start Maintenance...............................................................................1-10
Post Maintenance Steps.....................................................................1-10
Zero-Energy to Start-Up........................................................... 1-11
Getting Help from KVAL........................................................... 1-13
On-Line Help.......................................................................................1-13
Product Return Procedure ..................................................................1-13
Safety Sign-Off Sheet .............................................................. 1-16
A Note to the Operator........................................................................1-16
Chapter 2 Operation of the 979-2
Operator’s Tour........................................................................ 2-2
In-Feed Section ....................................................................................2-3
Foot Pedal ............................................................................................2-3
Operators Station..................................................................................2-4
Operators Station (Small Platform Screen)...........................................2-4
The Starts Saws Button ........................................................................2-5
Out-Feed...............................................................................................2-5
About the Electrical Panels...................................................... 2-6
Main Electrical Panel with VPN ............................................................2-6
Main Electrical Panel (Before VPN)......................................................2-7
About Using the VPN............................................................... 2-8
About the Safety Curtain.......................................................... 2-9
Description of the Six Light Panel ........................................... 2-10
Table Of Contents

979-2 Miter Trim Saw System
About Sensors ....................................................................................2-11
Quick Start ............................................................................... 2-12
Powering Operations for the 979-2.......................................... 2-14
How to Power Up the 979-2................................................................2-14
Home the 979-2..................................................................................2-15
How to Power Down the 979-2 ...........................................................2-16
Emergency Shutdown and Recovery .................................................2-16
About Modes.......................................................................................2-17
Mechanical Set Up................................................................... 2-18
Description of User Interface Screens ..................................... 2-20
Screen Selection Menu Map...............................................................2-20
Screen Selection Menu Map (Small Platform Screen) .......................2-21
Machine Feed Back ............................................................................2-22
About Lock-Outs (Option) ...................................................................2-22
Main Screen........................................................................................2-23
About the Software Start Saws Button (Older Machines) ...................2-23
About the Setup Screens......................................................... 2-26
About Calibration Data........................................................................2-26
Running a Reference Cut ...................................................................2-26
About Motion of Servo Motor ..............................................................2-26
Entering Calibration Data....................................................................2-27
About the Machine Calibration Screen ...............................................2-28
About Assigning a Pre-set ..................................................................2-30
About Manual Operation and Chipout Routine ........................ 2-31
Diagnostic Screen.................................................................... 2-33
Chapter 3 System IT Administration
System IT Administration......................................................... 3-2
About the 979-2 Computer ...................................................................3-2
Connections on the PLC.......................................................................3-2
Backing up the Computer .....................................................................3-3
Chapter 4 Maintenance of the 979-2
Maintenance Schedule ............................................................ 4-2
Maintenance NO-GOES .......................................................... 4-4
Lubrication Schedule ............................................................... 4-5
Typical Lucubration Kit..........................................................................4-5

KVAL 979-2 Operation / Service Manual
Lubrication Requirements........................................................ 4-6
Pillow Block Bearing Housings .............................................................4-6
Flange Bearing Housings .....................................................................4-7
Ball Rail Bearing ...................................................................................4-7
About Taper Bearings ...........................................................................4-8
Tapered Bearing Housings ...................................................................4-8
Ball Screw Nut ......................................................................................4-9
Ball Screw Drive Assembly...................................................................4-9
Pulley and Idler Shafts........................................................................4-10
Lubrication Points on the 979-2 ............................................... 4-11
Lubrication Points Heads...................................................................4-12
Replacing the Chipout Block.................................................... 4-13
Replacing Saw Blades............................................................. 4-14
Remove the Saw ................................................................................4-14
Description of Air Input System ............................................... 4-16
Air Input with Lubrication ...................................................................4-16
Air Line Without Lubricator .................................................................4-17
Mechanical Adjustments.......................................................... 4-18
979-2 Guard Placements and Purpose ..............................................4-18
Feed Dog Adjustment Procedure ......................................................4-20
Chapter 5 Troubleshooting the 979-2
About Motion Control ............................................................... 5-2
Basic Control Circuit .............................................................................5-2
Typical Positioning Systems .................................................................5-4
Troubleshooting Basics .......................................................... 5-7
Using Sensors to Trouble Shoot...........................................................5-7
Location of Sensors on 979-2.................................................. 5-8
Troubleshooting Electrical Problems ....................................... 5-9
If the Power Stops During Normal Operation........................................5-9
Troubleshooting with the Status Light Panel ......................................5-10
About VFD Troubleshooting ...............................................................5-15
Troubleshooting the Air Cylinders............................................ 5-16
Adjusting Cylinder Extension Speed:..................................................5-17
Adjusting Cylinder Retraction Speed: .................................................5-17
Adjusting Limit Switches.......................................................... 5-18

979-2 Miter Trim Saw System

1-1
CHAPTER 1 Introduction to the 979-2 Miter Trim Saw
System
This chapter provides an overview of the KVAL 979-2 Miter Trim Saw System and important
safety information to follow when operating the machine.
Chapter 1 at a Glance
Chapter 1 at a Glance ....................................................................................... 1-1
Overview of the 979-2 Miter Trim Saw System .............................................. 1-2
About this Manual ..................................................................................... 1-3
Safety First! ...................................................................................................... 1-4
Safety Sheet Sign-Off Sheet ...................................................................... 1-4
Safety Terminology of Labels .................................................................... 1-4
Safety Guidelines ....................................................................................... 1-4
Lockout Tagout Procedure ......................................................................... 1-8
Follow the P-R-O-P-E-R lockout rule of thumb. ..................................... 1-10
Zero-Energy to Start-Up ................................................................................ 1-11
Zero-Energy State to Start-Up to Operating State ................................... 1-11
Getting Help from KVAL .............................................................................. 1-13
On-Line Help ........................................................................................... 1-13
Product Return Procedure ........................................................................ 1-13
Safety Sign-Off Sheet .................................................................................... 1-16
A Note to the Operator: ........................................................................... 1-16

Overview of the 979-2 Miter Trim Saw System
1-2
KVAL 979-2 Operation/Service Manual
Overview of the 979-2 Miter Trim Saw System
KVAL model 979-2 Miter Trim Saw is designed to cut casing for doors and windows at rates up
to 25 pieces per minute for softwood material. Saws pivot between either 0- or 45-degree posi-
tions. The CNC index system will automatically compensate for cut length by adjusting the dis-
tance between saws.
The 979-2 saw heads cut down from above the face of the casing to eliminate any tear out on the
face.
There is also a chip-out support below the saw to prevent any deflection in thin casing as the saw
passes through it. This is especially important when cutting MDF casing, or pre-finished casing.
This design allows the scraps to drop below the machine into waste bins (Not included) without
assistance from compressed air nozzles. The air consumption of the 979-2 operating at maximum
capacity is only 8 CFM.
The 979-2 will miter side casing, with a 90 degree trim on the bottom, up to 98” long on the short
side of the miter. Head casing, mitered on both ends, can be cut as short as 12-3/8” measured on
the short side.
The feed hopper may be easily adjusted to accommodate material up to 4-1/2” wide and up to 1-1/
4” thick. The pieces of casing are fed from the hopper by a reciprocating dog system. The feed
dog systems on each carriage are tied together with a timing shaft to insure that each piece of cas-
ing is precisely positioned under the saws every time. Each cutting head is equipped with a 3 HP,
3450 RPM, TEFC, three phase motor. The saw motors have 1” diameter arbors.
Types of options available Are:
Option A: Spline Saw System
Cuts slots for kerf nail in head and leg casing miter.
Option B: Mitered ends on Door stop
Is capable of cutting mitered ends on door stop.
The Option G: Auto Calibrated Stops
Is an air operated system with calibrated stops that automatically adjust the movable carriage
when the saw heads are rotated.
Option Z: Computer Controlled Positioning
The 979-2 will be equipped with a computer driven servo motor to position the movable head.
The system will automatically compensate for the offsets when the cutting heads are switched
from 90 degrees to 45 degrees. The system will be controlled by a touch screen that will allow the
operator to simply enter the short side length of casing to cut. The finished length of the casing
will be correct for all saw head configurations.