Kval 990FX Operation manual

Innovation, Quality & Honesty
Operation and Service Manual
Published: 03/13/2018
990-FX Pre-Hanging Door System
990-FX Operation and Service Manual

KVAL 990-FX Operation/Service Manual
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call Kval Customer Support at [phone] or fax [phone]. Outside the
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Manual Part Number: 093_OPSRV_990FX_V5 (SN 17-93-28)
The 990-FX Door Hanging System is a trademark of Kval Incorporated.
Copyright 2014 Kval Incorporated. All rights reserved.
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KVAL 990-FX Operation/Service Manual
KVAL 990-FX Operation/Service Manual
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KVAL 990-FX Operation/Service Manual

KVAL 990-FX Operation/Service Manual
Table of Contents
Chapter 1 Introduction to the 990-FX Door Hanging System
Chapter 1 at a Glance.............................................................. 1-1
Overview of the 990-FX Door Hanging System....................... 1-2
Hopper Options.....................................................................................1-2
Table of Available Options ....................................................................1-3
About this Manual .................................................................................1-4
Safety First!.............................................................................. 1-5
Safety Sheet Sign-Off Sheet.................................................................1-5
Safety Terminology of Labels................................................................1-5
Safety Guidelines..................................................................................1-5
Lockout-Tagout Guidelines..................................................................................... 1-9
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9
Lockout Tagout Procedure....................................................... 1-10
Pre-Steps Before Lockout Tagout .......................................................1-10
Lockout Tagout Power ........................................................................1-10
Lockout Tagout Air Supply ..................................................................1-11
Start Maintenance...............................................................................1-11
Post Maintenance Steps .....................................................................1-11
Zero-Energy to Start-Up........................................................... 1-12
Getting Help from KVAL........................................................... 1-14
On-Line Help.......................................................................................1-14
Product Return Procedure..................................................................1-14
How to Download the Service Application ............................... 1-16
Download Application .........................................................................1-16
Safety Sign-Off Sheet .............................................................. 1-19
A Note to the Operator........................................................................1-19
Chapter 2 Operation of the 990-FX
About the Machine Line ........................................................... 2-2
Assembly Identification on Machine .....................................................2-3
Summary of the Controls on the Machine Line........................ 2-4
About the Operator Station ...................................................................2-4
Descriptions of Machine Controls .........................................................2-5
Controlling Access to User Screens .....................................................2-5

990-FX
Foot Pedal and Control Box..................................................................2-6
Hinges Loaded Button (Light Curtain Status Light)...............................2-7
Safety Controls ........................................................................ 2-8
Emergency Shutdown and Recovery ...................................................2-8
990-FX Light Curtain.............................................................................2-8
If the Beam is Broken ...........................................................................2-8
To Resume Normal Operation after an Beam is Broken.......................2-9
Air Brake on 990-FX Six Shooter........................................................2-10
Tour of the Machine ................................................................ 2-11
About the In-Feed Section ..................................................................2-11
About the Front Section......................................................................2-12
About the Hinge Carriage ...................................................................2-13
About the Six Shooter System............................................................2-14
About the Six Shooter Assembly ........................................................2-16
Driver Assembly..................................................................................2-18
About the Back Section ......................................................................2-19
Back View of Rear Section .................................................................2-20
About the Out-Feed ............................................................................2-21
About the Electrical Panels...................................................... 2-22
Main Electrical Panel ..........................................................................2-22
High Frequency Panels ......................................................................2-23
About the Nodes.................................................................................2-23
Graphical Sample of Node Connections.............................................2-24
Options .................................................................................... 2-25
Option BC: Ball Catch.........................................................................2-25
Option N: Dust Blow off System .........................................................2-25
8-0 Foot Door for FX...........................................................................2-26
About the Shift Function .....................................................................2-26
Option H: Securing Split Jambs ..........................................................2-27
Option Z: Screw Changing Hoppers ...................................................2-28
Description of the Six Light Panel .......................................... 2-29
Machine Start Summary .......................................................... 2-30
Initial Powering Operations for the 990-FX Line ...................... 2-33
How to Power Up the Line..................................................................2-33
Home the 990-FX ...............................................................................2-34
How to Power Down the Machine.......................................................2-35
Emergency Shutdown and Recovery .................................................2-35
To Resume Normal Operation after an E-Stop ...................................2-35
Description of User Interface Screens..................................... 2-36
Screen Selection Menu Map...............................................................2-36

KVAL 990-FX Operation/Service Manual
Machine Feed Back ............................................................................2-37
About the Main Screen ............................................................ 2-38
Machine Controls................................................................................2-39
Lock Group .........................................................................................2-42
About Manual Operation.......................................................... 2-43
Width Adjust........................................................................................2-44
Feed Manual Control ..........................................................................2-44
Lock Manual Control...........................................................................2-45
Hinge Manual Control .........................................................................2-45
Screw Delivery Manual Control ..........................................................2-46
About the Setup Screen........................................................... 2-47
Enter a Positive or Negative Number .................................................2-47
Entering Calibration Offsets................................................................2-48
Calibration Steps for the Lock Location ..............................................2-49
Lock Location Calibration ...................................................................2-49
Diagnostic Screen.................................................................... 2-52
Glossary of Common Terms .................................................... 2-54
Chapter 3 System IT Administration
System IT Administration......................................................... 3-2
About the Machine Computer...............................................................3-2
Connections on the PLC.......................................................................3-2
Network Diagram ..................................................................................3-3
Backing up the Computer .....................................................................3-3
About Remote Connection to KVAL Service.........................................3-4
Chapter 4 Maintenance of the 990-FX
Maintenance Schedule ............................................................ 4-2
300 Cycle Maintenance Steps ................................................. 4-4
Clean, Clean, Clean!.............................................................................4-4
600 Cycle Maintenance Steps ................................................. 4-5
Check Air Gauges and Inspect Water Traps ........................................4-5
Inspect Tooling......................................................................................4-5
Lubricate inside of Hopper....................................................................4-6
Empty Dust Collection Units .................................................................4-6
3,000 Cycle Maintenance Steps .............................................. 4-7
Inspect Feed Belts ................................................................................4-7
Inspect Screw Drop Tubes on Six Shooter...........................................4-7

990-FX
Inspect all Photo Eyes ..........................................................................4-7
Inspect Limit Switches ..........................................................................4-8
Inspect Screw Receiver Parts...............................................................4-8
Inspect Airlines .....................................................................................4-9
Refill Lubricators ...................................................................................4-9
Grease Ball Screw Bearings...............................................................4-10
Clean Bearing Shafts..........................................................................4-10
12,000 Cycle Maintenance Steps ............................................ 4-11
Inspect Chains for Proper Tension......................................................4-11
Inspect Air Cylinders...........................................................................4-11
Inspect Hydraulic Lines.......................................................................4-11
Inspect Ball Rail Shafts.......................................................................4-12
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........4-12
Clean inside Hopper ...........................................................................4-12
72,000 Cycle Maintenance Steps ............................................ 4-13
Inspect Nuts and Bolts........................................................................4-13
Check Door Feeding Transition ..........................................................4-13
Electrical .............................................................................................4-13
Computer Backup ...............................................................................4-13
Wash Filter and Lubricator Bowls .......................................................4-13
Tool Changing Schedule.......................................................... 4-14
Maintenance NO-GOES .......................................................... 4-16
Lubrication Schedule ............................................................... 4-17
Typical Lucubration Kit........................................................................4-17
Lubrication Schedule ............................................................... 4-18
Typical Lucubration Kit........................................................................4-18
Lubrication Requirements........................................................ 4-19
Pillow Block Bearing Housings ...........................................................4-19
Flange Bearing Housings ...................................................................4-20
Ball Rail Bearing .................................................................................4-20
About Taper Bearings .........................................................................4-21
Tapered Bearing Housings .................................................................4-21
Ball Screw Nut ....................................................................................4-22
Ball Screw Drive Assembly.................................................................4-22
Pulley and Idler Shafts........................................................................4-23
Lubrication Points on the 990-FX ............................................ 4-24
Back Section.......................................................................................4-26
Heads .................................................................................................4-27
Servo Motor Assembly........................................................................4-28
Description of Air Input System ............................................... 4-29

KVAL 990-FX Operation/Service Manual
Air Input with Lubrication ...................................................................4-29
Air Line Without Lubricator .................................................................4-30
Replacing Bits.......................................................................... 4-31
Replacing Bits in the Front Section ....................................................4-31
How to Access to Bit Assemblies .......................................................4-32
Remove and Replace the Screwdriver Bits ........................................4-34
Replacing Tooling in the Back Section..................................... 4-35
Option SB (CNC Back Section) ..........................................................4-36
Changing the Bore Drill.......................................................................4-36
Changing the Bolt Drill ........................................................................4-37
Collet Torque Values................................................................ 4-38
Chapter 5 Troubleshooting the 990-FX System
About Motion Control ............................................................... 5-2
Basic Control Circuit .............................................................................5-2
Troubleshooting Basics ........................................................... 5-4
Before you Adjust .................................................................................5-4
Before you Adjust .................................................................................5-5
Analyze the Sub Systems.....................................................................5-5
About a Typical Contactor Control ........................................... 5-7
About Contactor Troubleshooting .........................................................5-8
About Typical VFD Motor Drive Control................................... 5-9
About the VFD ....................................................................................5-10
About VFD Troubleshooting ...............................................................5-11
About a Typical Pneumatic Circuit ........................................... 5-12
Typical Pneumatic Assembly ..............................................................5-13
About the Coil (Solenoid)....................................................................5-13
About Cylinder Operation ...................................................................5-14
How the Pneumatic System Works ....................................................5-14
Important Notice about Adjusting Cylinder Speed ..............................5-16
Adjusting Cylinder Extend Speed .......................................................5-17
Adjusting Cylinder Retraction Speed ..................................................5-17
Valve Bank Locations .............................................................. 5-18
Location of Valve Banks on the Edge-SS ...........................................5-18
Typical Loads of Valve Banks .............................................................5-19
Troubleshooting Electrical Problems ....................................... 5-20
If the Power Stops During Normal Operation......................................5-20
Error Checking on the Variable Frequency Drives..............................5-21
Troubleshooting with the Status Light Panel ......................................5-21

990-FX
Using Sensors to Trouble Shoot.............................................. 5-26
Using Sensors to Trouble Shoot.........................................................5-26
Location of Sensors on 990-FX ..........................................................5-26
Z Axis and Y Axis Front Section Sensors...........................................5-28
X Axis Sensors Front Section .............................................................5-29
Network System Overview....................................................... 5-30
Connections to Servo Drives ..............................................................5-30
High Frequency Panel Node Connections..........................................5-31
Frame, Screw Driver, and Back Section Node Locations ...................5-32
Frame Node Connections...................................................................5-33
Screw Driver Nodes 1-3 (Opt 4) .........................................................5-33
Back Section Node .............................................................................5-33