Kval 990-F4 User manual

Innovation, Quality & Honesty
Operation Manual
Published: November 12, 2021
990-F4 Door Pre-Hanging System
990- F4 Operation Manual

KVAL 990-F4 Operation Manual
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for KVAL Inc. machines. Neither this Manual nor any of the information contained
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call Kval Customer Support at [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number:94-MV100.0
990-F4 is a trademark of Kval Incorporated.
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KVAL 990-F 4 Operation Manual
KVAL 990-F4 Operation Manual
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KVAL 990-F4 Operation Manual

KVAL 990-F4 Operation Manual
Table of Contents
Chapter 1 at a Glance.............................................................. 1-1
Overview of the 990-F4 ........................................................... 1-2
Options Available ..................................................................................1-3
About this Manual.................................................................................1-5
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
Download Application .........................................................................1-18
Safety Sign-Off Sheet .............................................................. 1-21
A Note to the Operator........................................................................1-21
Machine Description ................................................................ 2-2
The 990-F4 Process Summary.............................................................2-2
Machine Orientation..............................................................................2-2
Machine Components.............................................................. 2-3
Typical Production Line............................................................ 2-4
Operator’s Tour ........................................................................ 2-5
Standard 990-F4...................................................................................2-5
990-F4 with Dual Hopper......................................................................2-6

990-F4
Table of Contents
About the 990-F4..................................................................................2-7
About the In-Feed Section....................................................................2-7
About the Front Section........................................................................2-8
Option: Securing Split Jambs ...............................................................2-9
About the Operators Station ...............................................................2-10
About the Machine Control .................................................................2-11
About the Foot Pedal..........................................................................2-11
About the Hinge Carriage ...................................................................2-12
Front Section Gauges.........................................................................2-12
About the Six Shooter System............................................................2-13
About the Six Shooter Controls ..........................................................2-14
About the Hopper................................................................................2-15
Driver Assembly..................................................................................2-17
About the Overhead Track..................................................................2-18
About the Back Section: .....................................................................2-19
About the Electrical Panels...................................................... 2-21
Description of the Six Light Panel ......................................................2-22
Quick Start ............................................................................... 2-24
Powering Operations for the 990-F4........................................ 2-26
How to Power Up the 990-F4 .............................................................2-26
Home the 990-F4................................................................................2-27
How to Power Down the 990-F4.........................................................2-27
Emergency Shutdown and Recovery .................................................2-28
Menu Map of Interface Screens............................................... 2-29
Screen Selection Menu Map...............................................................2-29
Machine Feed Back............................................................................2-31
About the Main Screen ............................................................ 2-32
Machine Buttons.................................................................................2-33
Preset Buttons ....................................................................................2-34
Door Specs.........................................................................................2-34
Hinge Specs .......................................................................................2-34
Screw Setup Controls.........................................................................2-35
Lock Control Section...........................................................................2-35
About the Manual Screen ........................................................ 2-36
Test Mode ...........................................................................................2-36
Lock Jog .............................................................................................2-37
Table Jog ............................................................................................2-37
Hinge Jog............................................................................................2-38
Hopper Functions ...............................................................................2-38
About the Diagnostic Screen ................................................... 2-39

KVAL 990-F4 Operation Manual
Table of Contents
About Calibration ..................................................................... 2-40
Before you Calibrate...........................................................................2-40
Flow Chart of Calibration ...................................................................2-41
Using the Adjustment Menus ..............................................................2-42
Enter a Positive or Negative Number? ...............................................2-42
About the Entering Calibrations..........................................................2-43
Lock Location Process........................................................................2-44
Fast and Slow Lock Plate Timing........................................................2-45

990-F4
Table of Contents

Chapter 1 at a Glance
1-1
KVAL 990-F4 Operation Manual
CHAPTER 1 Introduction to the 990-F4
This chapter provides an overview of the KVAL 990-F4 System and important safety information
to follow when operating the machine.
Chapter 1 at a Glance
The following information is available in this chapter:
TABLE 1- 1. Summary of Chapter
Section Name Summary Page
Overview of the 990-F4
System
This section provides an overview of the 990-F4. 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 1-1
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 contact 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 1-21

Overview of the 990-F4
KVAL 990-F4 Operation Manual
1-2
Overview of the 990-F4
The 990-F4 is designed for both interior and exterior
doors and jambs. It will accommodate 1-3/8" and 1-3/
4" doors with a minimum width of 18" and a maximum
width of 48" and door lengths of 6' 8" or 8' 0". The
machining sequence includes automatic routing of
either 3-1/2" or 4" hinge pockets (see note below) on
both the door and jamb and complete cylindrical lock
machining, including faceplate. Cycle time is approxi-
mately 10 seconds. Hinges may be attached manually
or with the optional Six-Shooter or Eight-Shooter
Screw Gun while the door and jamb remain clamped in
position. Door-to-door productivity, including hinge
mounting, is typically 35-55 seconds. However, this
varies depending on the operator and material flow. Automatic width-adjust is included in the
base price.
The lock machining assembly will be positioned with a servo driven shaft screw. This is con-
trolled by a touch screen, and will allow settings for standard lock and dead bolt locations based
on the lock bore location. A third dead bolt bore may easily be added by entering the position on
the touch screen. In addition, custom lock bore and dead bolt locations may be entered on the
touch screen for any position within the travel of the servo driven screw.
The servo driven system will also automatically position the lock boring assembly when the door
hand is changed.
This machine is equipped with a solid state touch screen that replaces many of the mechanical
switches for the machine functions. The touch screen also includes the capability to view the sta-
tus of the various photo eyes and switches for quick diagnosis when needed, without having to
open the electrical panel or for the operator to leave his work station. The Touch Screen logic also
includes management functions such as Daily and Lifetime Totals.
KVAL's 990-F4 is the perfect marriage of our high-speed pre-hanging line with the additional flex-
ibility to machine 6'8" doors for three hinges and 8'0" doors with three hinges. Changeover from
one door height to the other takes only a couple of minutes and requires no tools. For even greater
flexibility, the 990-F4 can be equipped with the optional Six-Shooter to install 3-1/2" x 3-1/2"
hinges, as well as the optional Eight-Shooter for attaching 4" x 4" hinges. This machine is gener-
ally used in conjunction with the Handler Door Feeder, 700-C Assembly Machine with 8'0" door
capability, and the 960-3 Strike Jamb Router.