Kval 990-APEX User manual

Innovation, Quality & Honesty
Operation Manual
Published: December 14, 2022
990-APEX Operation Manual
990-APEX Door Machining System
Architectural, Pre-Hanging, and Exterior Doors
With KvalCAM®

KVAL 990-APEX Operation Manual
Proprietary Notice
This manual is confidential and contains proprietary information and intellectual 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 herein may be reproduced or disclosed under
any circumstances without the express written permission of Kval Inc. For authorization to copy
this information, please call Kval Technical Support at [phone] or fax [phone].
Manual Name: 990-APEX Operation Manual
Manual Revision: 233-MV100.0, 233-MV100.1, 233-MV100.2., 233-MV101.0
990-APEX is a trademark of Kval Incorporated.
KvalCAM® is a registered trademark of Kval Incorporated.
Copyright 2022 Kval Incorporated. All rights reserved.
Beckhoff®, TwinCAT, and EtherCat® are registered trademarks and are licensed by Beckhoff
Automation GmbH
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reserved. Reference to these products is not intended to imply affiliation with or sponsorship of
Kval Incorporated.
Contacting Kval
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email: pa[email protected]

KVAL 990-APEX Operation Manual
KVAL 990-APEX Operation Manual
Technical Support
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KVAL 990-APEX Operation Manual
NOTICE OF OWNERSHIP OF KvalCAM® SOFTWARE AND LIMITED LICENSE TO
USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KvalCAM SOFTWARE WHICH OPERATES
MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED
LICENSE TO USE THE KvalCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.
BY USING THE KvalCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED
LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE
KvalCAM SOFTWARE.
Kval Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are
the purchaser of Machinery operated by the KvalCAM Software are the “Licensee”.
The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM
Software” and further defined herein) which are used in the operation of the Machinery are licensed, not sold, to you
for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to you.
Licensor retains all ownership of the KvalCAM Software.
Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with, Inc. The Kval-
CAM Software is protected by copyright laws and treaties. Title and related rights in the content generated through
the KvalCAM Software are also the property of the Licensor and are protected by applicable law.
1. Definitions.
a.“KvalCAM Software” means the KvalCAM computer application installed in the Machinery
and written documentation and materials provided to you, as well as any revisions or updates of
such computer application and documentation.
b.“Install” means storing of the KvalCAM Software in the computer component of the Machin-
ery.
c.“Use” means executing the KvalCAM Software for purpose of operating the Machinery and
use of the documentation for properly operating KvalCAM Software.
2. Grant of License.
a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the Kval-
CAM Software upon payment of all amounts due for the purchase of the related Machinery.
b.Licensee will make no copies of the KvalCAM Software or alter the KvalCAM Software in
any way. Title to the KvalCAM Software will remain vested in Licensor, and nothing in this
License will give or convey any right, title or interest therein to Licensee except as a licensee.
c.Licensee agrees that it will use the KvalCAM Software or related documentation directly or
indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License
set forth herein.
d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or
disassemble the KvalCAM Software.
e.This License will terminate automatically if Licensee fails to comply with the limitations
described above.

990-APEX Operation Manual
Table of Contents
Chapter 1 Introduction to the 990-APEX System
Overview of the 990-APEX ...................................................... 1-2
Architectural, Pre-Hanging, & Exterior -- All in One ..............................1-2
KvalCAM...............................................................................................1-3
990-APEX Summary.............................................................................1-3
Specifications Summary .......................................................................1-4
About this Manual .................................................................... 1-5
Operation Manual .................................................................................1-5
Service Manual.....................................................................................1-5
KvalCAM Reference Manual ................................................................1-5
Safety First!.............................................................................. 1-6
Safety Sheet Sign-Off Sheet.................................................................1-6
Safety Terminology of Labels................................................................1-6
Safety Guidelines..................................................................... 1-7
Training.................................................................................................1-7
Protective Gear.....................................................................................1-7
When the Machine is Powered and Running........................................1-7
Compressed Air ....................................................................................1-8
Electrical ...............................................................................................1-8
Pinch Points........................................................................................1-10
Before Conducting Maintenance ........................................................1-10
Laser Warnings...................................................................................1-11
Compliance with Codes and Regulations...........................................1-11
Other Hazard Control Action...............................................................1-11
Follow Your Company’s Safety Procedures........................................1-11
Lockout Tagout Guidelines ...................................................... 1-12
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-12
Lockout Tagout Procedure....................................................... 1-13
Pre-Steps Before Lockout Tagout.......................................................1-13
Lockout Tagout Power ........................................................................1-13
Lockout Tagout Air Supply ..................................................................1-14
Start Maintenance...............................................................................1-14
Post Maintenance Steps.....................................................................1-14
Zero-Energy to Start-Up .......................................................... 1-16
Inspect ................................................................................................1-16
Clean Up.............................................................................................1-16
Replace Guards..................................................................................1-16
Check Controls ...................................................................................1-16
Remove Locks....................................................................................1-16
Perform Visual Checks .......................................................................1-16

990-APEX Operation Manual
Table of Contents
Close the Cage Gate ..........................................................................1-17
Getting Help from Kval............................................................. 1-18
Kval Return and Warranty Policy............................................. 1-19
Send the Item .....................................................................................1-19
Acceptance of Return .........................................................................1-19
Refund Turnaround Time....................................................................1-19
Kval Errors..........................................................................................1-19
Customer Errors .................................................................................1-20
Shipper Errors.....................................................................................1-20
Warranty Replacement Parts..............................................................1-20
Safety Sign-Off Sheet .............................................................. 1-22
A Note to the Operator........................................................................1-22
Chapter 2 Operation of the 990-APEX
Powering Operations for the 990-APEX .................................. 2-2
Steps Before Powering the 990-APEX .................................................2-2
Powering the APEX ..............................................................................2-3
Home the 990-APEX ............................................................................2-3
How to Power Down .............................................................................2-4
About Emergency Stops .......................................................... 2-5
To Resume Normal Operation after an E-Stop .....................................2-5
Other Safety Controls ...........................................................................2-5
Before Processing a Door........................................................ 2-6
About Processing a Door......................................................... 2-9
Process...............................................................................................2-12
About Machine Feedback ........................................................ 2-15
About the 990-APEX interface Screens................................... 2-16
Screen Tabs........................................................................................2-16
About the Main Control Screen................................................ 2-17
About the Machine Controls Section ....................................... 2-18
About the Main Control Section..........................................................2-19
About the Auto Control Section...........................................................2-20
About the Stop and Clamp Section.....................................................2-20
About the Sequence Control Section..................................................2-21
About the Manual Control Section......................................................2-22
About Speed Control ..........................................................................2-23
About the Job Parameters and Task Section........................... 2-24
About the Door Job Specification Top Bar ..........................................2-25

990-APEX Operation Manual
Table of Contents
About Hinge Task Controls .................................................................2-26
About Head Status..............................................................................2-27
About H-Block Locations ....................................................................2-27
About Hinge Cut Location and Length................................................2-29
About the Shelf Pin Config..................................................................2-30
Installing Shelf Pins ............................................................................2-31
About the Shooter Controls ................................................................2-32
About the Lock Tasks Control .............................................................2-33
About the Manual Servo Control Screen ................................. 2-35
Manual Servo Movement Direction.....................................................2-36
About the Tool Config Tabs...................................................... 2-38
Unlock the Tool Slot Configuration (Option)........................................2-38
About Using Tool Configuration ..........................................................2-38
To Unlock the Configuration................................................................2-39
To Lock the Configuration ...................................................................2-39
Enable or Disable a Tool.....................................................................2-39
About the Tool Parameters .................................................................2-40
Tool Config. Parameter Definitions .....................................................2-41
About the Tool Path Preview ................................................... 2-43
Tool Path Review Procedure ..............................................................2-43
About the Selected Path.....................................................................2-45
About the Display Window..................................................................2-45
About the Instructions Tab ..................................................................2-46
About the Options Tab ........................................................................2-47
About the Analysis Tab .......................................................................2-47
About the Json Tab .............................................................................2-48
About the Status Screen.......................................................... 2-49
About the Log Screen.............................................................. 2-50
Description of the Light Tower ................................................ 2-51
Chapter 3 Calibration of the Machine Line
About Calibration ..................................................................... 3-2
About the Calibration Menus and the Calibration Reference Cut.........3-2
Before you Calibrate.............................................................................3-2
About the 990-APEX Calibration Screen................................. 3-3
990-APEX Calibration Screen ..............................................................3-3
Calibration Sections..............................................................................3-3
Unlock the Calibration (Option).............................................................3-4
How to Enter Calibration Data ................................................. 3-5

990-APEX Operation Manual
Table of Contents
Enter a Positive or Negative Number? .................................................3-5
About The Calibration Box....................................................................3-5
About Restore Points............................................................................3-6
Starting the Calibration ............................................................ 3-7
Mechanical Calibrations........................................................................3-7
Tools Needed........................................................................... 3-8
Calibration Door Jobs ...........................................................................3-8
Step 1: About the Width Adjust Calibration .............................. 3-9
Tools Needed........................................................................................3-9
Verifying and Adjusting the Width Adjust Calibration ............................3-9
Step 2: About the Door Thickness Probe Calibration .............. 3-11
Tools Needed......................................................................................3-11
Verifying and Adjusting the Thickness Probe Calibrations..................3-11
Step 3: About the A-Side Door Stop Calibration ...................... 3-13
Tools Needed......................................................................................3-13
Verifying and Adjusting the A-Side Door Stop Calibration ..................3-13
Step 4: About the Hinge Carriage Calibration.......................... 3-15
Tools Needed......................................................................................3-15
Verifying and Adjusting the Hinge Carriage Calibration......................3-16
Step 5: About the Jamb Clamp Calibration.............................. 3-17
Tools Needed......................................................................................3-17
Jamb Clamp Parameters....................................................................3-17
Verifying and Adjusting the Jamb Clamp Calibrations ........................3-17
Step 6:About the Hinge Carriage Tool Calibrations ................. 3-19
Tools Needed......................................................................................3-19
About the Hinge Calibration Shape ....................................................3-19
Performing the Hinge Tooling Calibrations .........................................3-19
Verifying the Hinge Calibration Shapes ..............................................3-20
Adjusting the Hinge Shape Calibrations .............................................3-22
Step 7: About the Hinge Chisels Calibration............................ 3-23
Tools Needed......................................................................................3-23
About the Hinge Chisels Calibration Cut ............................................3-23
Performing the Hinge Tooling Calibrations .........................................3-24
Verifying the Hinge Chisels Calibration...............................................3-24
Adjusting the Hinge Chisels Calibrations............................................3-25
Step 8: About the B-Side Door Stop Calibration ...................... 3-26
Tools Needed......................................................................................3-26
About the B-Side Calibration Shape...................................................3-26
Verify and Adjust the B-Side Door Stop Calibration............................3-26

990-APEX Operation Manual
Table of Contents
Step 9: About the Lock Head X-Axis Calibration ..................... 3-28
Tools Needed......................................................................................3-28
Verify and Adjust the Lock Head X-Axis Calibration ...........................3-28
Step 10: About the Lock Edge Tools Calibration...................... 3-29
Tools Needed......................................................................................3-29
About Lock Edge Parameters.............................................................3-29
Performing the Lock Edge Tooling Calibrations..................................3-30
Verifying the Lock Edge Calibration Shape Location..........................3-30
Adjusting the Lock Edge Calibration Shape Location.........................3-31
Verifying the Lock Edge Lock Dimensions..........................................3-31
Adjusting the Lock Edge Calibration...................................................3-32
Step 11: About the Lock Face Tools Calibration ...................... 3-34
Tools Needed......................................................................................3-34
About the Lock Face Tools Calibration Shape....................................3-34
Performing the Lock Face Tooling Calibrations ..................................3-35
Verifying the Lock Face Calibration ....................................................3-35
Adjusting the Lock Face Calibration ...................................................3-36
Step 12: About the End Tools Calibration (Option) .................. 3-37
Tools Needed......................................................................................3-37
About the End Tools Calibration Shapes ............................................3-37
Performing the B-Side (LH) End Tooling Calibration ..........................3-38
Performing the A-Side (RH) End Tooling Calibration ..........................3-38
Verifying the B-Side (LH) End Tooling Calibration ..............................3-39
Verifying the A-Side (RH) End Tooling Calibration..............................3-39
Adjusting the End Tooling Calibration .................................................3-40
Chapter 4 Tour of the 990-APEX
Machine Terms ........................................................................ 4-2
Overview of Machine ............................................................... 4-4
990-APEX with Standard Hoppers .......................................................4-4
990-APEX with RTS Rotary Hoppers ...................................................4-5
About the Controls of the 990-APEX ....................................... 4-6
About the Operators Station .................................................................4-6
About KvalCAM ....................................................................................4-7
About the Door/Jamb Clamp Foot Pedal..............................................4-7
About the Local Machine Controls........................................................4-8
About Safety Controls.............................................................. 4-9
How to Resume Normal Operation after a Safety Shut down ..............4-9
About E-Stops.......................................................................................4-9

990-APEX Operation Manual
Table of Contents
About Laser Safety Scanners and the Safety Status Indicator...........4-10
About Gates Latches ..........................................................................4-11
About the Feed System ........................................................... 4-12
Feed System Part Descriptions ..........................................................4-13
About the Width Adjust ............................................................ 4-15
About the Door Thickness Modules......................................... 4-16
About the Clamping the Door .................................................. 4-17
About the Door Stops .........................................................................4-17
About Door Clamping .........................................................................4-18
About Back Section Door Clamping ...................................................4-19
About the Jamb Shelf .............................................................. 4-20
About Jamb Stops ................................................................... 4-21
About the Jamb Stop ..........................................................................4-21
About the Jamb Clamps .......................................................... 4-22
About the Jamb Swing............................................................. 4-23
Jamb Swing Part Identification ...........................................................4-23
Jamb Swing Part Descriptions............................................................4-24
Jamb Swing Stepper Motor System Part Identification.......................4-24
Jamb Swing Stepper Motor System Descriptions...............................4-25
About the Hinge Carriage ........................................................ 4-26
Hinge Carriage Part Locations............................................................4-27
Hinge Carriage System Part Descriptions ..........................................4-27
Hinge Tool Carriage Part Location......................................................4-29
Hinge Tool Carriage System Part Descriptions...................................4-29
About the Six/Eight Shooter System........................................ 4-31
Six/Eight Shooter System Part Descriptions.......................................4-31
Six/Eight Shooter Part Identification ........................................ 4-32
Six/Eight Shooter Part Descriptions....................................................4-32
About the Six/Eight Shooter Controls ...................................... 4-33
Control Panel Part Descriptions..........................................................4-34
About the Hopper..................................................................... 4-35
Hopper Part Descriptions....................................................................4-36
Hopper Process..................................................................................4-36
About the RTS Rotary Hopper................................................. 4-38
Operation ............................................................................................4-38
RTS Eight Shooter Option ..................................................................4-39
About the Driver Assembly ...................................................... 4-40
Driver Assembly Part Descriptions .....................................................4-41