Kval 990-APEX User manual

Innovation, Quality & Honesty
Service Manual
Published: October 24, 2022
990-APEX Service Manual
990-APEX Door Machining System
Architectural, Pre-Hanging, and Exterior Doors
With KvalCAM®

KVAL 990-APEX Service 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 Customer Support at [phone] or
fax [phone].
Manual Name: 990-APEX Service 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
All other products are trademarks or registered trademarks of their respective holders, all rights
reserved. Reference to these products is not intended to imply affiliation with or sponsorship of
Kval Incorporated.
Contacting KVAL
For further information about this manual or other Kval Incorporated products, please contact us.
Mailing address:
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
Phone and Fax:
call: [phone]
fax: [phone]
General Office Business Hours
Mon-Thu:6:00 AM - 4:00 PM PST
Fri: 6:00 AM - 3:30 PM PST
Parts
Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web-
site at the “Contact Us” page.
email: pa[email protected]

KVAL 990-APEX Service Manual
KVAL 990-APEX Service Manual
Technical Service Support
For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact
Us” page.
Mon-Fri:4:00 AM - 4:00 PM PST
email: [email protected]
Field Service Support
For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the
“Contact Us” page.
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Sales Support
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the “Contact Us” page.
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Kval Website
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releases), learn about our machine software solutions, download machine documentation, view
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http://www.kvalinc.com

KVAL 990-APEX Service 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.
, 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 Service Manual
Table of Contents
Introduction to the 990-APEX System 1
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 .........................................................................................1-10
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