Kval 990-H User manual

Innovation, Quality & Honesty
Operation Manual
Published: 10/24/18
990-H Pre-Hanging Door System
990-H Operations Manual

KVAL 990-H 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 Customer Support at [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number: DOC_137_3_OP
The 990-H Pre-Hanging Door System is a trademark of Kval Incorporated.
Copyright 2014 Kval Incorporated. All rights reserved.
Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed
by Beckhoff Automation GmbH
Windows CE® is a registered trademark of Microsoft Corporation.
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
Customer Service: For further information about this manual or other Kval Incorpo-
rated products, contact the Customer Support Department
• Mailing address:
Customer Support Department
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
• Phone and Fax:
In the U.S and Canada, call [phone] or fax [phone]
Outside the U.S. and Canada, call [phone] or fax [phone]
• Business hours:
Technical Support:
6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
Parts & Service Sales:
6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]

KVAL 990-H Operation Manual
KVAL 990-H Operation Manual
Your Feedback is Welcome: To help us design products that make your job easier
and your business more successful, we'd like to gain your perspective about your user
experience with our product - that is, the manual, the machinery, the software, etc.
What was easy or difficult to use or to learn? If you could change something about the
design, what would it be? Please email your comments and suggestions for improve-
ment to [email protected]. (NOTE: This is not a customer support email
link. For that, please refer to the Customer Service contact information above.) Thank
you!
http://www.kvalinc.com

KVAL 990-H Operation Manual

Table of Contents
KVAL 990-H Operation Manual
Chapter 1 Introduction to the 990-H
Chapter 1 at a Glance.............................................................. 1-1
Overview of the 990-H Door Hanging System ........................ 1-2
Operation ..............................................................................................1-2
Features................................................................................................1-2
Options and Specials Available ............................................................1-4
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
On-Line Help.......................................................................................1-15
Product Return Procedure ..................................................................1-15
How to Download the Service Application ............................... 1-17
Download Application .........................................................................1-17
Safety Sign-Off Sheet .............................................................. 1-20
A Note to the Operator........................................................................1-20
Chapter 2 Operation of the 990-H
The 990-H Process Summary ................................................. 2-2
Machine Orientation..............................................................................2-2
Typical Production Line Layout.............................................................2-2
Machine Components.............................................................. 2-3
Top View of Machine................................................................ 2-4
About the Operator Station and Front Section Controls .......... 2-5
About the Foot Pedal and Control Box .................................................2-6
Control Box ..........................................................................................2-6

990-H
Table of Contents
Hinges Loaded Button (Status Light)....................................................2-7
About the In-Feed Section ....................................................... 2-8
About the Front Section ........................................................... 2-9
About the Hinge Heads.......................................................................2-10
About the Six Shooter System................................................. 2-11
About the Hopper................................................................................2-11
About the Six Shooter Assembly ........................................................2-14
About the Driver Assembly .................................................................2-15
About the Back Section ........................................................... 2-16
Front and Rear Views of the Back Section .........................................2-17
About the Out-Feed ................................................................. 2-18
About the Electrical Panels...................................................... 2-19
Electrical Panel Option: Servo Box 2..................................................2-20
Description of the Six Light Panel ........................................... 2-21
Machine Start Summary .......................................................... 2-22
Powering Operations for the 990-H ......................................... 2-25
How to Power Up the 990-H ...............................................................2-25
Home the 990-H .................................................................................2-26
How to Power Down the 990-H ..........................................................2-26
Safety Controls ........................................................................ 2-27
Emergency Shutdown and Recovery .................................................2-27
To Resume Normal Operation after an E-Stop ...................................2-27
Air Brake on 990-FX Six Shooter........................................................2-27
Summary of the Interface ........................................................ 2-29
Machine Control and Calibration Screens ..........................................2-29
Machine Feed Back ................................................................. 2-31
Controlling Access to User Screens ...................................................2-31
Main Screen............................................................................. 2-32
Main Screen Descriptions...................................................................2-32
Manual Operation .................................................................... 2-36
Manual Jog Screen.............................................................................2-36
About the Entering Data into the Setup Screens ..................... 2-40
How to Enter Calibration Data ............................................................2-40
Enter a Positive or Negative Number? ...............................................2-41
Setup Screen ........................................................................... 2-42
Main Calibration Screen Descriptions.................................................2-42
Setup Hinges 1-3 Screens....................................................... 2-45

Table of Contents
KVAL 990-H Operation Manual
About the Pre-Drill Screen ....................................................... 2-49
Entering Pre-Drill Pattern Data ...........................................................2-49
Example of Data Input ........................................................................2-50
Diagnostic Screen.................................................................... 2-51
Status of I/O and E-Stops Screen............................................ 2-52

990-H
Table of Contents

Chapter 1 at a Glance
1-1
KVAL 990-H Operation Manual
CHAPTER 1 Introduction to the 990-H
This chapter provides an overview of the KVAL 990-H Door Hanging System and important
safety information to follow when operating the machine.
Chapter 1 at a Glance
Section Name Summary Page
Overview of the System This section provides an overview of the 990-H. 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 IMPORTANT: Procedure to Lockout Tagout equipment
when it is being serviced.
page 1-11
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
How to Download the
Service Application
Procedure to download an interactive application to
allow Service Technician to control your machine and
help troubleshoot.
page 1-17
Safety Sign-Off Sheet A record to track operators that are trained on the
machine.
page 1-20

Overview of the 990-H Door Hanging System
KVAL 990-H Operation Manual
1-2
Overview of the 990-H Door Hanging System
The Kval Model 990-H will rout a door and jamb for two or three hinges, drill pilot holes for the
hinge screws, rout and bore for the lock and apply hinges.
Functions include hinge and faceplate routing and boring for lock and bolt. Standard features
include automatic hinge routing, pre-drill, and hinge application for two or three hinge butts on
both door and jamb. Machine also includes automatic door width adjustment to accommodate
mixed stacks and automatic door positioning with a two-speed feed belt system.
Operation
Door is automatically positioned while the operator loads and clamps a single hinge stile (single
hinge jamb), or jamb set complete with strike jamb and head jamb. Routing and boring occur
while the operator places hinges into the nests of the applicators. Pressing the “IN” button fastens
all hinges simultaneously.
Features
Routs two or three hinge pockets in both door and jamb, spaced so half hinges can be
mounted without pins.
Pre-drills two or three hinge pockets in both door and jamb.
Applies two or three hinges to door and jamb with the hinge separated.
Number 1, 2 & 3 hinge router assemblies are movable on THK® linear ball rail to accommo-
date 2040mm (80.31), 2240mm (88.188) & 2340mm (92.126)doors. The assemblies will be
cylinder operated and will index with 4 position stop turrets that will be manually revolved to
accommodate both door and hinge length
Hinge Routers are 1hp 3ph Hi-Frequency motors (230/380v)
Both hinge jamb stop assemblies are movable on THK® rail to accommodate 2040mm
(80.31), 2240 (88.188) & 2340mm (92.126) jambs. (Cylinder operated)
Machine will accommodate nominal door thickness of 35mm (1.377) and 40mm (1.588) with
some variation expected.
Machine will be equipped with one in-feed and two out-feed door stops that will register off of
the top of the door. The center and right hand hinge routers and screw driver heads will be
cylinder operated and will move into position to machine and apply hinges to the 2040mm,
2240 and the 2340mm door lengths
Auto positioning.
Auto width adjust.
Two independent face bore drill units to eliminate chip out. (1 top and 1 bottom 5hp drill
motors) adjustable manually from 60-70mm from the door edge