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.
Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed
by Beckhoff Automation GmbH
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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:
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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.