Kval 990FX User manual

Innovation, Quality & Honesty
Service Manual
Published: January 16, 2020
990-FX Pre-Hanging Door System
With the RTS-FX Rotary Hopper System

KVAL 990-FX Operation/Service 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_SRV_990FX_V6
The 990-FX Door Hanging System is a trademark of Kval Incorporated.
Copyright 2020 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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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/Service Manual
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KVAL 990-FX Operation/Service Manual

Table of Contents
KVAL 990-FX Operation Manual
Chapter 1 Introduction to the 990-FX
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
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 System IT Administration
System IT Administration......................................................... 2-2
Backing up the Computer.....................................................................2-3
Procedure for Backing up Data.............................................................2-3
Chapter 3 Maintenance of the 990-FX
Maintenance Schedule............................................................ 3-2
300 Cycle Maintenance Steps................................................. 3-4
Clean, Clean, Clean!.............................................................................3-4
600 Cycle Maintenance Steps................................................. 3-5
Check Air Gauges and Inspect Water Traps ........................................3-5

KVAL 990-FX Operation Manual
Table of Contents
Inspect Tooling......................................................................................3-5
Lubricate inside of Hopper....................................................................3-6
Empty Dust Collection Units.................................................................3-6
3,000 Cycle Maintenance Steps.............................................. 3-7
Inspect Feed Belts................................................................................3-7
Inspect Screw Drop Tubes on Six Shooter...........................................3-7
Inspect all Photo Eyes..........................................................................3-7
Inspect Limit Switches..........................................................................3-8
Inspect Screw Receiver Parts...............................................................3-8
Inspect Airlines .....................................................................................3-9
Refill Lubricators...................................................................................3-9
Grease Ball Screw Bearings...............................................................3-10
Clean Bearing Shafts..........................................................................3-10
12,000 Cycle Maintenance Steps............................................ 3-11
Inspect Chains for Proper Tension......................................................3-11
Inspect Air Cylinders...........................................................................3-11
Inspect Hydraulic Lines.......................................................................3-11
Inspect Ball Rail Shafts and Ball Screws............................................3-12
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........3-12
Clean inside Hopper...........................................................................3-12
72,000 Cycle Maintenance Steps............................................ 3-13
Inspect Nuts and Bolts........................................................................3-13
Check Door Feeding Transition..........................................................3-13
Electrical.............................................................................................3-13
Computer Backup...............................................................................3-13
Wash Filter and Lubricator Bowls.......................................................3-14
Tool Changing Schedule.......................................................... 3-15
Maintenance NO-GOES.......................................................... 3-16
Lubrication Schedule............................................................... 3-17
Typical Lucubration Kit........................................................................3-17
Lubrication Requirements........................................................ 3-18
Pillow Block Bearing Housings...........................................................3-18
Flange Bearing Housings ...................................................................3-19
Ball Rail Bearing.................................................................................3-19
About Taper Bearings.........................................................................3-20
Tapered Bearing Housings .................................................................3-20
Ball Screw Nut....................................................................................3-21
Ball Screw Drive Assembly.................................................................3-21
Pulley and Idler Shafts........................................................................3-22
Lubrication Points on the 990-FX ............................................ 3-23

Table of Contents
KVAL 990-FX Operation Manual
Back Section.......................................................................................3-25
Heads .................................................................................................3-26
Servo Motor Assembly........................................................................3-27
Hubs ........................................................................................ 3-28
Jamb Transfer Grease Points.................................................. 3-30
Description of Air Input System ............................................... 3-31
Air Input with Lubrication ...................................................................3-31
Air Line Without Lubricator .................................................................3-32
Replacing Bits.......................................................................... 3-33
Replacing Bits in the Front Section ....................................................3-33
How to Access to Bit Assemblies .......................................................3-34
Remove and Replace the Screwdriver Bits........................................3-36
Replacing Tooling in the Back Section..................................... 3-37
Option SB (CNC Back Section)..........................................................3-38
Changing the Bore Drill.......................................................................3-38
Changing the Bolt Drill........................................................................3-39
Chipout Block Replacement .................................................... 3-40
Burn Chipout.......................................................................................3-40
To Replace the Back Section Chipout Block............................ 3-41
To Replace the Front Section Chipout Block........................... 3-42
Summary of Burn Process..................................................................3-42
Chipout Block Spacers........................................................................3-42
Procedure to change Front Chipout Block..........................................3-43
Collet Torque Values................................................................ 3-45
Chapter 4 Troubleshooting the 990-FX System
About Motion Control............................................................... 4-2
Basic Control Circuit.............................................................................4-2
Troubleshooting Basics ........................................................... 4-4
Before you Adjust .................................................................................4-4
Before you Adjust .................................................................................4-5
Analyze the Sub Systems.....................................................................4-5
About a Typical Contactor Control........................................... 4-7
About Contactor Troubleshooting.........................................................4-8
About Typical VFD Motor Drive Control................................... 4-9
About the VFD....................................................................................4-10
About VFD Troubleshooting ...............................................................4-11

KVAL 990-FX Operation Manual
Table of Contents
About a Typical Pneumatic Circuit........................................... 4-12
Typical Pneumatic Assembly..............................................................4-13
About the Coil (Solenoid)....................................................................4-13
About Cylinder Operation ...................................................................4-14
How the Pneumatic System Works ....................................................4-14
Important Notice about Adjusting Cylinder Speed..............................4-16
Adjusting Cylinder Extend Speed .......................................................4-17
Adjusting Cylinder Retraction Speed..................................................4-17
Troubleshooting Electrical Problems....................................... 4-18
If the Power Stops During Normal Operation......................................4-18
Error Checking on the Variable Frequency Drives..............................4-19
Troubleshooting with the Status Light Panel ......................................4-19
Using Sensors to Trouble Shoot.............................................. 4-24
Using Sensors to Trouble Shoot.........................................................4-24
Location of Sensors on 990-FX..........................................................4-24
Z Axis and Y Axis Front Section Sensors...........................................4-26
X Axis Sensors Front Section.............................................................4-27
Network System Overview....................................................... 4-28
Connections to Servo Drives..............................................................4-29
High Frequency Panel Node Connections..........................................4-30
Frame, Screw Driver, and Back Section Node Locations...................4-31
Frame Node Connections...................................................................4-31
Screw Driver Nodes 1-3......................................................................4-31
Back Section Node.............................................................................4-32

Notes:

Chapter 1 at a Glance
1-1
KVAL 990-FX Service Manual
CHAPTER 1 Introduction to the 990-FX
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 Service 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 or (Opt four) 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.
Hopper Options
Standard three head option with
Hoppers affixed to the top of the
Screw Heads
Four Head special to accommodate
8 foot doors. Hoppers are ground
level for easy access. Bins allow
stocking of different colored
screws.

Overview of the 990-FX Door Hanging System
1-3
KVAL 990-FX Service Manual
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.
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.
Three Head machine with the
Rotary Hopper stand. The Rotary
option allows kind change of screw
type with preloaded screws.

Overview of the 990-FX Door Hanging System
KVAL 990-FX Service 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 Service 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 Service 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 Service 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 Service 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 Service 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 Service 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 Service 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.