Kval 965X User manual

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

KVAL 965-X System Operation Manual
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Manual Part Number: DOC-228-1-OP
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K VA L 965-X System Operation Manual
K VA L 965-X System Operation Manual
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KVAL 965-X System Operation Manual
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USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KvalCAM SOFTWARE WHICH OPERATES
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Table of Contents
965X Operation Manual
Overview of the 965X 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
KVAL Return and Warranty Policy ........................................... 1-16
Send the Item .....................................................................................1-16
Acceptance of Return .........................................................................1-16
Refund Turnaround Time....................................................................1-16
Kval Errors..........................................................................................1-16
Customer Errors .................................................................................1-17
Shipper Errors.....................................................................................1-17
Warranty Replacement Parts..............................................................1-17
How to Download the Service Application ............................... 1-18
On-Line Help.......................................................................................1-18
Download Application .........................................................................1-18
Safety Sign-Off Sheet .............................................................. 1-22
A Note to the Operator........................................................................1-22
About the 965X ........................................................................ 2-2
Shape and Special Cut Highlights ........................................................2-2
Jamb Data Properties...........................................................................2-3
965X Jamb Basics................................................................................2-4
Summary of Machining a Jamb ............................................... 2-5
Step 1: Start the Process......................................................................2-5
Step 2: Steps Before Processing Jamb................................................2-5
Step 3: Create or Load a Door Job.......................................................2-6
Step 4: Open the Main 965X Screen....................................................2-6
About Processing the Jamb..................................................................2-7

965X Operation Manual
Table of Contents
Step 5: Load the Jamb..........................................................................2-7
Step 6: Align and Clamp the Jamb .......................................................2-8
Step 7: Start Sequence.........................................................................2-8
Step 8: Next Group, Next Job, or End Process ....................................2-9
Powering Operations for the 965X........................................... 2-10
How to Power Up the 965X ................................................................2-10
Home the 965X.................................................................................. 2-11
How to Power Down ...........................................................................2-11
About Emergency Stops.....................................................................2-12
To Resume Normal Operation after an E-Stop ...................................2-12
Other Safety Controls .........................................................................2-12
About the Computer Setting ...............................................................2-12
About Machine Status Feedback............................................. 2-13
About the 965X interface Screens ........................................... 2-14
Screen Tabs........................................................................................2-14
About the Main Control Screen................................................ 2-15
Machine Controls Section........................................................ 2-16
About the Main Control Section..........................................................2-17
About the Sequence Control Section..................................................2-18
About Jamb Clamp and Jamb Stop Section .......................................2-19
About Speed Control ..........................................................................2-19
About the Jamb Support Selection .....................................................2-20
About the Jamb Support Blocks .........................................................2-20
Job Parameters and Task Section ........................................... 2-21
About the Top Bar ...............................................................................2-22
Jamb Specs........................................................................................2-22
Current Group.....................................................................................2-22
Status Message..................................................................................2-22
About the Tasks Screen......................................................................2-23
Task Display to Jamb Cut Example ....................................................2-23
About the Task Box.............................................................................2-24
Fractional Display or Decimal Display ................................................2-24
About the Cut Icons ............................................................................2-25
About the Process Box .......................................................................2-25
About the Skip Cut Check Box ...........................................................2-25
How to Change the Jamb Reference Display.....................................2-26
About Rollover Parameter Information ...............................................2-26
About Timers.......................................................................................2-27
About the Manual Servo Control Screen ................................. 2-28
Manual Axis Head Movement Direction..............................................2-28

Table of Contents
965X Operation Manual
About the Tool Config Tabs ...................................................... 2-29
Unlock the Tool Slot Configuration (Option)........................................2-30
About Using Tool Configuration ..........................................................2-30
Enable or Disable Tool........................................................................2-31
About the Tool Path Preview Test Screen................................ 2-32
About Viewing G-Code .......................................................................2-33
About the Status Screen.......................................................... 2-34
About the Log Screen.............................................................. 2-35
Description of the Light Tower ................................................ 2-36
About Calibration ..................................................................... 3-2
About the Calibration Menus and the Calibration Reference Cut.........3-2
Before you Calibrate.............................................................................3-2
About the Calibration Tabs....................................................... 3-3
Access to the Calibration Adjustments .................................................3-3
Unlock the Calibration (Option).............................................................3-4
Enter a Positive or Negative Number? .................................... 3-5
How to Enter Calibration Data ................................................. 3-6
About The Calibration Box....................................................................3-6
About Restore Points............................................................................3-7
About the 965X Calibration Screen ......................................... 3-8
965X Calibration Screen.......................................................................3-8
Calibration Selections...........................................................................3-8
About Calibration Sequence .................................................... 3-9
Step 1: Check the Carriage Location....................................... 3-10
Procedure ...........................................................................................3-10
Step 2: Calibrate the Stops...................................................... 3-11
Procedure to Calibrate the Stops........................................................3-11
Step 3: Calibrate the Tools....................................................... 3-12
Tool Locations.....................................................................................3-12
Calibration Reference Cut ..................................................................3-13
Process to Calibrate the Tools ............................................................3-13
Router Calibration Reference Cut.......................................................3-14
Sample Calibration Cut.......................................................................3-15
Predrill.................................................................................................3-16
Sample Calibration Chisels Cut..........................................................3-17
Routers: How to Isolate and Calibrate a Specific Router......... 3-18
Example Of a Calibration Cut .............................................................3-19
Front View of the 965X ............................................................ 4-2

965X Operation Manual
Table of Contents
Operator’s Station and Controls on the 965X .......................... 4-3
Operator’s Station.................................................................................4-3
Front Section Controls..........................................................................4-4
User Interface .......................................................................................4-4
Foot Pedal Control................................................................................4-5
Assemblies on the Carriage Head ........................................... 4-6
Tool Set in the Carriage Head...............................................................4-6
Carriage Head Rear View.....................................................................4-7
Servo Axis Direction..............................................................................4-7
965X Jamb Clamps ................................................................. 4-8
Jamb Clamp Assembly Detail ...............................................................4-8
Jamb Support Blocks on the Vertical Jamb Clamp.................. 4-9
Jamb Support Block Storage................................................................4-9
Safety Light Curtain ............................................................................4-10
If the Beam is Broken .........................................................................4-10
To Resume Normal Operation after an Beam is Broken.....................4-10
About Sensors ......................................................................... 4-11
Sensor Locations on Machine ............................................................4-11
Frame Sensors ...................................................................................4-11
Carriage Head Sensors ......................................................................4-12
Location of Servo Motors and Valve Bank Locations .............. 4-13
Servo Motor Locations........................................................................4-13
Valve Bank Locations .........................................................................4-13
About the Electrical Panels...................................................... 4-14
965X Main E-Panel.............................................................................4-14
About Nodes ............................................................................ 4-15
Typical Block Diagram of Network Connections .................................4-15
Graphical Sample of Node Connections and Power Distribution .......4-16

1-1
965X Operation Manual
CHAPTER 1 Introduction to the 965X System
Chapter 1 at a Glance
The following information is available in this chapter:
Section Name Summary Page
Overview of the 965X Jamb
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 1-15
Safety Sign-Off Sheet A record to track operators that are trained
on the machine.
page 1-22

Overview of the 965X System
1-2
965X Operation Manual
Overview of the 965X 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 965X 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 965X, 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.