Kval 990FX User manual

Innovation, Quality & Honesty
Operation Manual
Published: May 21, 2019
990-FX Pre-Hanging Door System

KVAL 990-FX Operation Manual
Proprietary Notice
This Manual is confidential and contains proprietary information and intellectual
property of KVAL Inc., and i s 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: 093_OP_990FX_V4
The 990-FX Door Hanging System is a trademark of Kval Incorporated.
Copyright 2014 Kval Incorporated. All rights reserved.
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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:
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Parts & Service Sales:
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6:30 AM to 1:30 PM Pacific Standard Time, Friday
(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]

KVAL 990-FX Operation/Service Manual
KVAL 990-FX 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-FX Operation Manual

Table of Contents
KVAL 990-FX Operation Manual
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
Table of Available Options ....................................................................1-2
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
Line System Process ............................................................................2-2
Assembly Identification on Machine .....................................................2-3
Photo of 990-FX and RTS-FX Setup ....................................................2-4
About the RTS-FX ................................................................................2-4
About the Jamb Transfer Machine........................................................2-5
Summary of the Controls on the Machine Line........................ 2-6
About the Operator Station ...................................................................2-6
Descriptions of Machine Controls .........................................................2-7
Controlling Access to User Screens .....................................................2-7
Foot Pedal and Control Box..................................................................2-8

KVAL 990-FX Operation Manual
Table of Contents
Hinges Loaded Button (Light Curtain Status Light)...............................2-9
Safety Controls ........................................................................ 2-10
Emergency Shutdown and Recovery .................................................2-10
990-FX Light Curtain...........................................................................2-10
If the Beam is Broken .........................................................................2-10
To Resume Normal Operation after an Beam is Broken.....................2-11
Air Brake on 990-FX Six Shooter........................................................2-12
Tour of the Machine ................................................................2-13
About the In-Feed Section ..................................................................2-13
About the Front Section......................................................................2-14
About the Hinge Carriage ...................................................................2-15
About the Six Shooter System............................................................2-16
About the Six Shooter Assembly ........................................................2-18
Driver Assembly..................................................................................2-19
About the Back Section ......................................................................2-20
Back View of Rear Section .................................................................2-21
About the Out-Feed: ...........................................................................2-22
About the Electrical Panels.................................................................2-23
Description of the Six Light Panel ........................................... 2-25
Machine Start Summary .......................................................... 2-26
Initial Powering Operations for the 990-FX Line ...................... 2-29
How to Power Up the Line ..................................................................2-29
Home the 990-FX ...............................................................................2-30
How to Power Down the Machine.......................................................2-31
Emergency Shutdown and Recovery .................................................2-31
To Resume Normal Operation after an E-Stop ...................................2-31
Description of User Interface Screens ..................................... 2-32
Screen Selection Menu Map...............................................................2-32
Machine Feed Back ............................................................................2-33
About the Main Screen ............................................................ 2-34
Machine Controls................................................................................2-35
Lock Group .........................................................................................2-38
About Manual Operation.......................................................... 2-39
Jog Controls........................................................................................2-40
Screw..................................................................................................2-41
Carousel .............................................................................................2-41
Lock ....................................................................................................2-41
Feed....................................................................................................2-42
About the Setup Screen........................................................... 2-43
Enter a Positive or Negative Number .................................................2-43

Table of Contents
KVAL 990-FX Operation Manual
Entering Calibration Offsets................................................................2-44
Calibration Steps for the Lock Location ..............................................2-45
Lock Location Calibration ...................................................................2-45
Diagnostic Screen.................................................................... 2-49
Door Count .........................................................................................2-50
Appendix: Machine Component Terms.................................... 2-51

KVAL 990-FX Operation Manual
Table of Contents

Chapter 1 at a Glance
1-1
KVAL 990-FX Operation Manual
CHAPTER 1 Introduction to the 990-FX Door Hanging
System
This chapter provides an overview of the KVAL 990-FX 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 990-FX
System
This section provides an overview of the 990-FX This
section includes a general description and a table of
available options
page 1-2
Safety! IMPORTANT safety information is described in this
section
page 1-4
Zero-Energy to Start-Up Procedure to power up your machine for the first time. page 1-12
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 1-14
Safety Sign-Off Sheet A record to track operators that are trained on the
machine.
page 1-19

Overview of the 990-FX Door Hanging System
KVAL 990-FX Operation Manual
1-2
Overview of the 990-FX Door Hanging System
KVAL's 990-FX is the fastest and most productive pre-hanging system available in the industry.
The 990-FX will rout a door and jamb for three or four hinges, drill pilot holes for the hinge
screws, mortise for the lock, and apply three 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 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 the hinge jamb.
Routing and boring occur while the operator places hinges into the nests of the three hinge appli-
cators. Pressing the "In" button fastens all three hinges simultaneously. Price includes operator
training and machine checkout by a KVAL technician in the customer's plant.
Table of Available Options
For detailed information about available options, please contact our KVAL Sales and Service
department.
Option Title Description
Option C Pushbutton Selection for Face Bore
Backsets
For two face bore backsets between 2-3/8" and 2-3/4". Manual
adjustment takes 5 to 10 minutes.
Option DC Dust Take-Off Rees-Memphis Model C730-2 dust collection fan and filter with
silencer and magnetic starter. 7.5HP totally enclosed fan cooled
motor wired for 3 phase voltage. Each tube collector includes a
cartridge filter with 322 square feet of blended media in place of
standard 25 sq. ft. filter bags.
Option H Split Jamb Stapler Clamps and fires two wide-crown staples to fasten the male and
female hinge jambs members together during the routing
sequence. Requires staple gun which is not included in the price.
Please note that this option reduces the minimum width of a door
that can be machined to 18
Option I Reverse Feed Facing the hinge routers, the normal feed direction is left to right.
Option IL Door Hand Indicator Light Light will be mounted on the out-feed end of the 990-FX that
can be seen by the 700-C Assembly Table operator. The light will
be on when the door in the 990-FX is being machined as a right
hand door and off for a left hand door.
Option N Dust Blow off System Air blow-off tube cleans dust and chips from the top of a door.
Option T High-Frequency Hinge Routers Three 1 HP 230/380v high-frequency hinge routers and drive
units with 1/2" collet.
Option U High-Frequency Bolt Plate Router One 1 HP 230/380v high-frequency bolt plate router with drive
unit and 1/2" collet.
Option Z Screw Changing Hoppers Screw-changing hoppers for changing screw colors. Price
includes three 6-slot screw hoppers.

Overview of the 990-FX Door Hanging System
1-3
KVAL 990-FX Operation Manual
Option Tooling and Lubricant Package Please review with your KVAL consultant to determine your
needs.
Option Spare Parts Package Please review with your KVAL consultant to determine your
needs.
Option Title Description

Overview of the 990-FX Door Hanging System
KVAL 990-FX Operation Manual
1-4
About this Manual
This manual is part of a package delivered with the machine line.
Operation Manual includes the following:
Chapter Title Description
Chapter 1 Introduction Descriptions of Machine Line and Safety
Information.
Chapter 2 Operation Descriptions of how to power machine
line, and operator interface user screens.
Chapter Title Description
Chapter 1 System IT Brief description of Computer and PLC in
the Machine
Chapter 2 Maintenance Maintenance steps for the machine line
Chapter 3 Trouble Shooting Troubleshooting tips and theory of opera-
tion.
Service Manual includes the following:

Safety First!
1-5
KVAL 990-FX Operation Manual
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-19.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-
vide safety information to operators. Safety labels should be clearly visible to the operator and
must be replaced if missing, damaged, or illegible.
There are three types of warning labels or decals:
•DANGER means if the danger is not avoided, it will cause death or serious injury.
•WARNING means if the warning is not heeded, it can cause death or serious
injury.
•CAUTION means if the precaution is not taken, it may cause minor or moderate
injury.
Safety Guidelines
In addition to the caution and warning labels affixed to this machine, follow the guidelines below
to help ensure the safety of equipment and personnel.
This machine is a powerful electro-mechanical motion control
system. You should test your motion system for safety under
all potential conditions. Failure to do so can result in dam-
age to equipment and/or serious injury to personnel.
Ensure that all employees who operate this machine
are aware of and adhere to all safety precautions
posted on the machine and are trained to operate this
machine in a safe manner.
Training

Safety First!
KVAL 990-FX Operation Manual
1-6
Never operate the machine without proper eye and
ear protection.
Protective Gear
• Never reach hands beyond safety cage. Servo
motors can unexpectedly move quickly.
• Never clear screws or hinges out of the machine
while it is running.
• Never reach into the router area to retrieve a
hinge. The router may still be running down
after shut down.
• Never perform any maintenance unless machine
is at zero state.
• Never clean the machine while it is running.
• Never walk away from the machine while it is
running.
When the Machine is ON
The compressed air system connected to this
machine should have a three-way air valve
for shut-off and pressure relief.
All cylinders on machine are under high
pressure and can be very dangerous when
activated. Before performing any mainte-
nance or repairs on this machine turn off the
main air disconnect. Lockout and tagout
this connection.
See “Lockout Tagout Procedure” on
page 1-10.
Compressed Air

Safety First!
1-7
KVAL 990-FX Operation Manual
Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, you must install an
approved disconnect for the
electrical power supplying this
machine.
When opening the cabinet you must first turn off the
disconnect switch. When the cabinet door is open there
is still power on the top side of the disconnect switch.
Some machines are powered by more than one supply
located at different locations. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
Prior to performing any maintenance, repairs,
cleaning or when clearing jammed debris, you
must disconnect, tag out, or lock out the electrical
and air pressure systems. This should be done in
accordance with applicable state and/or federal
code requirements.
Before Conducting Maintenance
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the
manufacturers safety precautions.

Safety First!
KVAL 990-FX Operation Manual
1-8
KVAL advises that you request an on-site state
safety review of your installation of this
machine. This is to ensure conformance to any
additional specific safety and health regula-
tions which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP pro-
duction. It is your responsibility to immediately protect
your employees against any such hazard.
Additional detailed safety guidelines are included in the
operating instructions of this manual. KVAL will be
pleased to review with you any questions you may have
regarding the safe operation of this machine
Follow Your Company’s Safety Procedures
In addition to these safety guidelines. Your company
should have on-site and machine specific safety proce-
dures to follow.

Lockout-Tagout Guidelines
1-9
KVAL 990-FX Operation Manual
Lockout-Tagout Guidelines
• Place a tag on all padlocks. On the tag, each
operator must put their own name and date.
(These locks are only to be removed by the
person who signs the tag)
• If more than one person is working on the
machine, each additional person places a lock
and tag on each disconnect.
• Only each operator may remove their own
lock and tag.
Important: When many people are all working
on the same machine you will need a multiple
lockout device, such as the one shown here.
Follow the P-R-O-P-E-R lockout rule of thumb.
P...... Process shutdown
R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)
O...... OFF! Shut off all power sources and isolating devices
P...... Place lock and tag
E...... ENERGY: Release stored energy to a zero-energy state
R ...... Recheck controls and test to ensure they are in the “OFF” state

Lockout Tagout Procedure
KVAL 990-FX Operation Manual
1-10
Lockout Tagout Procedure
This policy is required by OSHA regulation 1910.147 and Cal OSHA’ S
SB198 ruling of July 1991.
Use the following lockout procedure to secure this machine while it is
powered down. During a lockout, you disconnect all power and shut
off the air supply. Be sure to use the tagout guidelines noted below.
Pre-Steps Before Lockout Tagout
Lockout Tagout Power
1. Evaluate the equipment to fully understand all energy sources (multiple electrical
supplies, air supply and pressure, spring tension, weight shifts, etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration of the
shutdown.
3. Obtain locks, keys, and tags from your employer’s lockout center.
4. Turn off machine. See Chapter 2 for power down and power up procedures.
5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF
position. Then push the red tab to pop it out. Place a padlock through the hole.
Place your tag on the padlock, as per the tagout guidelines below. (see illustration
below).
Power
Note: When multiple people are working on the machine, each person needs to
have a lock on the handle in the extra holes provided.
Insert Lock into hole.
Turn Switch to the
OFF position
Lock and Tag out

Lockout Tagout Procedure
1-11
KVAL 990-FX Operation Manual
Lockout Tagout Air Supply
Start Maintenance
7. Once the locks and tags are in place and all personnel are clear, attempt to operate
the machine to ensure equipment will not operate.
8. Maintenance or repairs may started.
Post Maintenance Steps
9. After maintenance is completed, the person performing the work must ensure all
tools, spare parts, test equipment, etc., are completely removed and that all guards
and safety devices are installed.
10. Before removing the locks and tags, the person who attached them shall inspect the
equipment to ensure that the machine will not be put in an unsafe condition when
re-energized.
11. The lock and tag can now be removed (only by the person(s) who placed them),
and the machine can be re-energized.
12. The tags must be destroyed and the locks and keys returned to the lockout center.
6. Turn all air valves to the OFF position and place a pad-
lock through the hole (see illustration below).
NOTE: Place your tag on the padlock, as per the
tagout guidelines.

Zero-Energy to Start-Up
KVAL 990-FX Operation Manual
1-12
Zero-Energy to Start-Up
Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of
safety.
Start-up Guidelines
The following guidelines below should be followed to start the equipment.
Inspect
The equipment must be inspected for proper adjustment before starting equipment.
Clean Up
All materials and debris must be cleaned up. Any combustible materials or old parts
used during repairs must be cleaned up and/or properly disposed of.
Replace Guards
Replace all equipment guards. If part of equipment cannot be properly adjusted after
start-up with guard on, contact the KVAL Service team. See “Getting Help from
KVAL” on page 1-14.
Check Controls
Confirm that all switches are in the “OFF” position. Please be advised that some com-
ponents of the machine may start automatically when energy is restored.
Remove Locks
Each operator must remove his or her own lock and tag. This will ensure that all oper-
ators are in a safe place when the equipment is started.
Perform Visual Checks
If the equipment is too large to see all around it, station personnel around the area and
sound the personnel alarm before starting the equipment. If your operation is more
complex, your company’s comprehensive safety procedure may involve additional
steps. You will need to ask your supervisor about these procedures. The company’s
lockout procedure should be posted at each machine. On larger or long-term mainte-
nance or installation projects, the company’s procedures must be explained to all new
operators and a copy of the company’s procedures should be posted on-site for the
duration of the work.
The Company’s procedures should also include provisions for safely handling shift
changes and changes in operators or new operators.Comprehensive lockout/tagout
may use a gang box or other system to ensure that locks are secure and not removed
without authorization.