Kval 990FX User manual

1. After Jamb is secure, press the Jamb
Clamp Foot Pedal to clamp the Jamb
2. Press the Start Se-
quence button.
3. Load the hinges, one for each of the
three Six-Shooter heads with the
hinge pin towards the top of the door.
4. Move out of area beyond the Light
Curtain
5. Press the Hinge Loaded button to
start the process.
6. When the Status Light is o󰀨, enter the
staging area and process next door.
Power UP Each Machine
1. Verify the area of operation is clear and safe to
machine product.
2. Ensure factory air is applied to machine and
main air supply is turned on.
3. Verify that all E-Stop buttons are
OUT and Gates are CLOSED.
4. Turn the Electrical Disconnect to
the ON positions each Electrical
Cabinet.
5. Turn the Control Transformer
On.
6. Initiate the START MACHINE
button (Approximately 3 minute Boot-
up)
See reverse for 6 Lights description
Operation Guide
990-FX Line
Press the Hinge Loaded button
to startup the process
Select the Home Machine Button. After all ma-
chine is Homed, the machine status will display
Idle in the Machine Feedback Status box.
Select the correct Preset. Verify that the informa-
tion is correct.
For Example: Check Door Width, Check Auto Feed is
enabled, Auto Width is enabled, Check Jamb Pusher is
Enabled, and Auto Door Width is Enabled.
Set the Door Hand.
• RH (Right Hand Door)
• Auto (Automatically receives
data)
• LH (Left Hand Door)
1. Pull jamb from Stack
Area
2. Load Jamb on top of
ledge pressing tightly
against fence.
• The Hinges Loaded button acts like a Reset Button for the Light
Curtain.
• Do Not Enter the staging area with a solid light displayed on the
Status Light. This will shut down the machine. The machine will
have to be reset and re-homed.
• A steady 1 blink rate is permissible to enter staging area and
start to process a door.
• A steady 2 blink rate, perform Homing Routine.
• A steady 3 blink, check air pressure gages and verify it is correct
through-out the machine. (Shop Air may be low, Check Sole-
noids, Air Cylinders, or Lubricators)
• A steady 4 blink, check air brakes , switches, sensors, or brake
release valve on air input.
• A steady 5 blink, check limit switches or travel of assembly.
• A steady 6 blink , check if all power is on or have a qualied
technician,check fuses, power supplies or voltage connections
990-FX Quick Start Rev 1
Boot-Up
After the computer is
completed booting up,
the Interface will start
automatically.
Set-Up Process
Load Jamb
Hinge
Loaded
Button
View
Status
Light
Tips (Blink Codes)

Get a Service Technician to log on to the machine and help troubleshoot.
• Have a good detailed summary of the issue.
• Ensure Machine has Internet Connection
• Contact KVAL Service and start a ticket
(Call (800)- 553-5825 or start a support ticket Online https://www.kvalinc.com/support)
• Have tools ready (DVM and Tool Kit)
Get to the Suppot AP to allow Tech to Logon
• Exit the Kval program. On the Main Screen select then select
• On the Windows Screen select the KVAL Service Icon
• Follow instructions from Kval Service Tech.
Machine Terminology
Electrical
Panels
Electrical Panels contain the brains and power for the machine. The Main Electrical Panel contains the
main PLC and sevo drivers to control the sevo motors. The High Frequency Panels contain the VFD’s to
drive the routers, width adjust, and feed motors.
Door Clamp The Door Clamp secures the door for stable routing and drilling.
Jamb Clamp The Jamb Clamp secures the jamb for stable routing and drilling.
Door Stop The Door Stop sets a reference for the door to be in the correct position for processing.
Jamb Stop The Jamb Stop sets a reference for the jamb to be in the correct position for processing. Is located on the
front section of the machine and is set manually by the operator.
Routers Routers are located in the Carriage Heads and on the Back Section. The routers rout the hinge pockets and
rout face plates. Typically Carriage Heads contain wo routers that cut in opposite directions to create a
smooth cut.
Pre-drills The pre-drills are located in the Carriage Heads. They pre-drill the screw holes for hinge screw application
on the door and the jamb.
Bolt Drill The bolt drill is located on the Back Section. Drills a bolt hole on the lock edge of the door.
Lock Bore The lock bore is located on the Back Section. Drills a lock hole on the face of the door.
Chisels(Opt) Chisels are located in the Carriage Heads and the Back Section. The chisels square corners on the hinge
pockets and the lock plate.
Chip-Out
Block
Chip-Out Blocks are located under some drills to reduce tear-out on the edges of the cut.
Tools
Operator’s
Station
The Operator’s Station is the inteface of operator to machine. It contains power controls and touch
screen inteface to control the cuting parameters of the door.
Machine
Control
Located mid machine, manually set Feed (Auto-Man), LH or RH door, Stat or Stop machine.
Door Clamp
Pedal
The Door Clamp pedal is a foot pedal that activates the door clamp to either clamp or unclamp the door.
Jamb Clamp
Pedal
The amb lamp pedal is a foot pedal t activates the jamb clamp to either clamp or unclamp the jamb.
Six-Shooter The Six-Shooter is located at the right side of the machine. Six-Shooters apply hinges and secures them
with screws (3x3 patern)
Eight-Shooter
(Opt K)
The Eight-Shooter is located at the let side of the machine. Eight-Shooters apply hinges and secures
them with screws (4x4 patern)
Stat
This light turn on when
the Machine Stat buton is
pressed and the ACR Relay is
latched.
Stop
This light will be on if
Machine Stop buton is deac-
tivated.
.
E-Stop
If the light is NOT on,
ensure gates are closed and all
E-Stops are not activated
24VDC
Light turns on once the
ACR is latched and the 24VDC
Power Supply is working.
Powers the PLC.
Tips
Light NOT ON Steps to Ty
Control Power Check Main Power to the machine
Ensure the Control Circuit Buton is ON
Tech: (Lock/Tagout) Ensure the Disconnect Switch in the Panels is ON
Tech: (Lock/Tagout) Check Control Transformer
Over Load Relay Tech: (Lock/Tagout) Check Overload Relays on Contactors
E-Stop Ensure ALL E-Stops are in the OUT position.
Ensure ALL Safey Gates are closed and Light Cutain feedback is error free.
Tech:(Lock/Tagout) Check resistance of E-Stop circuit
Stop Ensure Stop Buton is not stuck
Tech: (Lock/Tagout) Check resistance of Stop circuit
Stat Ensure Stat Buton is making connection
Tech: (Lock/Tagout) Check ACR Circuit
24VDC Tech: (Lock/Tagout) Check voltage into and out of the 24VDC power supply
About the 6-Lights
Machine Operation
Light turns on when the Control Trans-
former power is working, Indicates power
on seconday side-of transformer and High
Power is applied to all components
Control Power
The overload circuit is working when
light is on.
verload Relay
High Voltage may cause injury or death.
Troubleshooting checks must be performed
by a Qualied Electrical Technician.
Remote Troubleshooting
For Technicians: Get detailed troubleshooting information on the 6 Lights. (See a video ,Download a PDF)
Video (6-LightsTroubleshooting): htps://www.kvalinc.com/videos/training
PDF (6-Lights Troubleshooting): htps://www.kvalinc.com/machine-suppot