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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call Kval Customer Support at [phone] or fax [phone]. Outside the
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Manual Part Number: DOC-146_3-OPS
The 979-2 Miter Trim Saw System is a trademark of Kval Incorporated.
Copyright 2006 Kval Incorporated. All rights reserved.
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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.

Overview of the 979-2 Miter Trim Saw System
1-3
KVAL 979-2 Operation/Service Manual
About this Manual
This manual contains operation information and service and maintenance information.
It includes identification of machine assemblies, power-up and power-down steps, and informa-
tion about using the user interface.
The Troubleshooting and Maintenance sections are directed toward qualified service
technicians
TABLE 1- 1.
Title Part Number
979-2 Operation and Service Manual DOC-146_3-OPS

Safety First!
1-4
KVAL 979-2 Operation/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 1-16.
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!
1-5
KVAL 979-2 Operation/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 1-9.
Compressed Air

Safety First!
1-6
KVAL 979-2 Operation/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!
1-7
KVAL 979-2 Operation/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
1-8
KVAL 979-2 Operation/Service Manual
Lockout-Tagout Guidelines
• Place a tag on all padlocks. On a 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, then 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
1-9
KVAL 979-2 Operation/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
1-10
KVAL 979-2 Operation/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.

Zero-Energy to Start-Up
1-11
KVAL 979-2 Operation/Service Manual
Zero-Energy to Start-Up
Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of
safety.
Start-up Guidelines
The following guidelines below should be followed to start the equipment.
Inspect
The equipment must be inspected for proper adjustment before starting equipment.
Clean Up
All materials and debris must be cleaned up. Any combustible materials or old parts
used during repairs must be cleaned up 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, contact the KVAL Service team. See “Getting Help from
KVAL” on page 1-13.
Check Controls
Confirm that all switches are in the “OFF” position. Please be advised that some com-
ponents of the machine may start automatically when energy is restored.
Remove Locks
Each operator must remove his or her own lock and tag. This will ensure that all oper-
ators are in a safe place when the equipment is started.
Perform Visual Checks
If the equipment is too large to see all around it, station personnel around the area and
sound the personnel alarm before starting the equipment. If your operation is more
complex, your company’s comprehensive safety procedure may involve additional
steps. You will need to ask your supervisor about these procedures. The company’s
lockout procedure should be posted at each machine. On larger or long-term mainte-
nance or installation projects, the company’s procedures must be explained to all new
operators and a copy of the company’s procedures should be posted on-site for the
duration of the work.
The Company’s procedures should also include provisions for safely handling shift
changes and changes in operators or new operators.Comprehensive lockout/tagout
may use a gang box or other system to ensure that locks are secure and not removed
without authorization.

Zero-Energy to Start-Up
1-12
KVAL 979-2 Operation/Service Manual
Remember, lockout/tagout procedures work because you are the only one with the key
to your lock. Proper lockout/tagout can save lives, limbs, and money. Help make your
work environment safe for you and your fellow workers. Be sure to follow the P-R-O-
P-E-R lockout/tagout procedures, and that those around you do also.
Close the Cage Gate
Verify all cage gates are securely closed. Ensure all safety protocols are in effect.