Kval 990FX User manual

Innovation, Quality & Honesty
990FX Operational
Reference Manual
Published:
March 28, 2007 REV. 1.2

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
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protected by laws pertaining to such materials. This document, the information in this document, and all rights
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762-0485. Outside the U.S. and Canada, call [phone].
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KVAL 2007 and 990FX are trademarks of Kval, Incorporated.
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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 Incorporated products, contact
the Customer Support Department
•http://www.kvalinc.com/customer_service.html (lists all the representatives, including email
addresses and phone numbers)
•Mailing address:
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Kval Incorporated
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Petaluma, CA 94952
•Phone and Fax:
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•Business hours:
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This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Table of Contents
ABOUT THIS GUIDE.....................................................................................................................................................5
Audience................................................................................................................................................................. 5
How This Guide Is Organized................................................................................................................................ 5
Related Publications.............................................................................................................................................. 5
Printed Documentation ............................................................................................................................. 5
CHAPTER 1: INTRODUCTION .....................................................................................................................................7
Uncrating the 990FX .............................................................................................................................................. 7
Receiving the 990FX....................................................................................................................................... 7
Uncrating Setup.............................................................................................................................................. 7
Tools Required:......................................................................................................................................... 7
Uncrating Procedure ...................................................................................................................................... 7
Anchoring the 990FX ............................................................................................................................................. 8
Overview of the 990FX........................................................................................................................................... 9
Operation ........................................................................................................................................................ 9
Safety First! ............................................................................................................................................................ 9
Lock-Out/Tag-Out Procedure ...................................................................................................................... 10
Lock and Tag-Out Guidelines ................................................................................................................. 12
CHAPTER 2: SETTING UP THE 990FX .....................................................................................................................13
Front Section........................................................................................................................................................ 13
Setting Up Hinge Centers ............................................................................................................................ 13
Preliminary Hinge Center Set-Up ............................................................................................................ 13
Positioning H-Blocks ............................................................................................................................... 13
Centering Routers Within the H-Block..................................................................................................... 13
Setting Up the Hinge Backset...................................................................................................................... 14
Setting the Doorstops .................................................................................................................................. 14
Back Section ........................................................................................................................................................ 14
Setting Up Lock Height ................................................................................................................................ 15
Setting Up Lock Bore Backset .................................................................................................................... 15
If No Auto Backset on 990FX: Side Drill (Latch Hole)............................................................................... 16
Lock Bore Diameter...................................................................................................................................... 16
Plate Width: Plate Router Vertical Travel.................................................................................................... 16
Plate Router Depth ....................................................................................................................................... 16
Adjust Plate Router for Three-Degree Bevel Set..................................................................................... 16
Adjust Plate Router from Three-Degree Bevel Set to Zero-Degree Bevel Set......................................... 17
CHAPTER 3: AUTO RUN WALKTHROUGH ..............................................................................................................19
General Operation................................................................................................................................................ 19
Machine Orientation ............................................................................................................................................ 19
Back Section / Front Section ....................................................................................................................... 19
Machine Components .................................................................................................................................. 19
Auto Run............................................................................................................................................................... 20
Preliminary Setup ......................................................................................................................................... 20
Review of Safety Information .................................................................................................................. 20
Review of Machine Orientation Information............................................................................................. 20
Review of Safety Stickers on the 990FX ................................................................................................. 20
Safety Hooks .......................................................................................................................................... 20
Auto Door/LH-RH.................................................................................................................................... 21
Emergency Stop ..................................................................................................................................... 21
Load Screws ........................................................................................................................................... 21
Powering On the 990FX ............................................................................................................................... 21
Control Transformer:............................................................................................................................... 21

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Start ........................................................................................................................................................ 21
The Operator’s Station: Touchscreens....................................................................................................... 21
Main Menu Touchscreen.............................................................................................................................. 21
Auto Run Touchscreen ................................................................................................................................ 22
Auto Feed ............................................................................................................................................... 22
Feed OFF ............................................................................................................................................... 22
Auto Unclamp OFF/ON: .......................................................................................................................... 22
Auto Width OFF/ON................................................................................................................................ 22
Door Setup.............................................................................................................................................. 22
Door Setup Touchscreen ............................................................................................................................. 22
Bolt Drill .................................................................................................................................................. 22
Lock Bore................................................................................................................................................ 22
Faceplate ................................................................................................................................................ 23
Router/FP Continue Run......................................................................................................................... 23
Route Jamb ............................................................................................................................................ 23
Route Door ............................................................................................................................................. 23
Pre-Drill................................................................................................................................................... 23
Previous Menu ........................................................................................................................................ 23
Screwdriver Setup Touchscreen ................................................................................................................. 23
Off........................................................................................................................................................... 23
Left & Right ............................................................................................................................................. 23
All............................................................................................................................................................ 24
Previous Menu ........................................................................................................................................ 24
Loading and Clamping the Jamb ................................................................................................................ 24
Loading the Hinges ...................................................................................................................................... 24
990FX Control Box ....................................................................................................................................... 24
Start Sequence .......................................................................................... Error! Bookmark not defined.
Hinges Loaded........................................................................................................................................ 24
CHAPTER 4: TOUCHSCREENS.................................................................................................................................25
Touchscreen Walkthrough—Four Operational Touchscreens......................................................................... 25
Main Menu Touchscreen.............................................................................................................................. 25
1. Auto Run Touchscreen ............................................................................................................................ 25
1.1. Feed Off ........................................................................................................................................... 26
1.2 Auto Feed ......................................................................................................................................... 26
1.3 Feed Thru ......................................................................................................................................... 26
1.4 Machine OK/Machine Error ............................................................................................................... 26
1.5 Reset Error........................................................................................................................................ 26
1.6 Auto Unclamp OFF/ON ..................................................................................................................... 26
1.7 Door Clamp....................................................................................................................................... 27
1.8 Door Stop.......................................................................................................................................... 27
1.9 Auto Width OFF/ON .......................................................................................................................... 27
1.10 Router/FP Continue Run ................................................................................................................. 27
1.11 Manual Run..................................................................................................................................... 27
1.12 Screwdriver Setup........................................................................................................................... 27
1.13 Door Setup...................................................................................................................................... 27
1.14 Previous Menu ................................................................................................................................ 27
2. Manual Run Touchscreen ........................................................................................................................ 27
2.1 Feed Mode: Auto/Feed Thru ............................................................................................................. 28
2.2 Jog REV............................................................................................................................................ 28
2.3 FAST/SLOW ..................................................................................................................................... 28
2.4 Jog FWD........................................................................................................................................... 28
2.5 Auto Width OFF/ON .......................................................................................................................... 28
2.6 Jog OPEN ......................................................................................................................................... 29
2.7 Jog CLOSE ....................................................................................................................................... 29
2.8 Shift Router Out of Pocket ................................................................................................................ 29
2.9 Door Stop.......................................................................................................................................... 29
2.10 Clamp ............................................................................................................................................. 29
2.11 Burn Chipout ................................................................................................................................... 29
2.12 Previous Menu ................................................................................................................................ 29
3. Door Setup Touchscreen ......................................................................................................................... 30
3.1 Faceplate Ext. Time .......................................................................................................................... 30
3.2 Bolt Drill ............................................................................................................................................ 30
3.3 Lock Bore.......................................................................................................................................... 30
3.4 LockBore Deep ................................................................................................................................. 30
3.5 2 ¾”............................................................................................................................................... 30

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
3.6 Faceplate .......................................................................................................................................... 30
3.7 Router/FP Continue Run ................................................................................................................... 31
3.8 Route Jamb....................................................................................................................................... 31
3.9 Route Door........................................................................................................................................ 31
3.10 Split Jamb Nailer ............................................................................................................................. 31
3.11 Pre-Drill OFF/ON ............................................................................................................................ 31
3.12 Previous Menu ................................................................................................................................ 31
4.1 OFF................................................................................................................................................... 32
4.2 Left & Right ....................................................................................................................................... 32
4.3 ALL ................................................................................................................................................... 32
4.4 OFF................................................................................................................................................... 32
4.5 Left.................................................................................................................................................... 32
4.6 Center ............................................................................................................................................... 32
4.7 Right ................................................................................................................................................. 33
4.8 Clear Screws..................................................................................................................................... 33
4.9 Blow Screws ..................................................................................................................................... 33
4.10 Screw Drop Off ............................................................................................................................... 33
4.11 Shift Screwdrivers ........................................................................................................................... 33
4.12 Reload Screws................................................................................................................................ 33
4.13 Previous Menu ................................................................................................................................ 33
990FX Control Box ....................................................................................................................................... 33
Start Sequence ....................................................................................................................................... 33
Auto Door/LH-RH.................................................................................................................................... 34
Hinges Loaded........................................................................................................................................ 34
Unclamp.................................................................................................................................................. 34
Emergency Stop ..................................................................................................................................... 34
Operating the 990FX ............................................................................................................................................ 34
CHAPTER 5: MAINTENANCE ....................................................................................................................................37
Maintenance Schedule for 990FX ....................................................................................................................... 37
Daily............................................................................................................................................................... 37
Weekly........................................................................................................................................................... 37
Monthly ......................................................................................................................................................... 37
May and December Check Ups ................................................................................................................... 37
Lubrication Requirements................................................................................................................................... 38
Linear Bearings ............................................................................................................................................ 38
Flange Bearing ............................................................................................................................................. 38
Lubricate special high speed bearings....................................................................................................... 38
Perske High Frequency Motors................................................................................................................... 38
Approved Lubrication Products .................................................................................................................. 38
Lubricator Adjustments ............................................................................................................................... 39
Gear Motor Lubrication Requirements ....................................................................................................... 39
Priming the Lubricator ................................................................................................................................. 39
Replacing Screwdriver Bits................................................................................................................................. 40
CHAPTER 6: GENERAL OPERATIONAL TROUBLESHOOTING.............................................................................41
Hinge Dropped During Application .................................................................................................................... 41
Hinge Dropped Behind Router Head During Application ................................................................................. 41
APPENDIX A: LOCATIONS FOR PHOTO EYES, SENSORS, LIMIT SWITCHES, AND INPUT AND OUTPUT
NODES ........................................................................................................................................................................45
Troubleshooting Touchscreens.......................................................................................................................... 45

990FX Operational Reference Manual, Rev. 1.2, 2007 5
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
About This Guide
This guide describes how to operate the 990FX, a numerically controlled door cut-out system.
Audience
This guide is written for machine operators and factory technicians who are responsible for
operating the 990FX machine.
How This Guide Is Organized
This guide is organized as follows:
Chapter 1: “Introduction”
Provides a brief introduction to 990FX and identifies safety precautions and procedures.
Chapter 2: “Basic Operation”
Provides and introduction to the operator features, and provides procedures for accomplishing
basic operator tasks.
Related Publications
Printed Documentation
In addition to this Operational Reference Manual, the following documents are provided with the
product.
Document Description Location (in addition to online)
990FX Unpack
and Installation
Guide
Provides guidelines and
procedures for site prep,
unpacking, positioning, and
installing the 990FX system
•Top-most item inside the “Open Me
First” box, found on the out-feed end
of the 990FX machine (as shipped)
•System Reference binder
System
Schematics
Complete electrical schematics
for the 990FX system
System Reference binder (look for the
separate tab for this item)