Kval 994-X User manual

Innovation, Quality & Honesty
Includes Option RTS
994-X Pre-Hanging Door System
994-X Pre-Hanging Door System
Operation Manual
Published: 1/19/22

KVAL 994-X Operation Manual
Proprietary Notice
This Manual is confidential and contains proprietary information and intellectual
property of KVAL Inc., and is 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: DOC-204_3-OP (Start at SN 028)
The 994-X Door Hanging System is a trademark of Kval Incorporated.
Copyright 2022 Kval Incorporated. All rights reserved.
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rated products, contact the Customer Support Department
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Kval Incorporated
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KVAL 994-X Operation Manual
KVAL 994-X Operation Manual
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KVAL 994-X Operation Manual

Table of Contents
Kval 994-X Operation Manual
Chapter 1 Introduction to the 994-X System
Overview of the 994-X Door Hanging System ......................... 1-2
Available Options..................................................................................1-3
About this Manual .................................................................... 1-6
Safety First!.............................................................................. 1-7
Safety Sheet Sign-Off Sheet.................................................................1-7
Safety Terminology of Labels................................................................1-7
Safety Guidelines..................................................................................1-7
Lockout-Tagout Guidelines ...................................................... 1-11
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-11
Lockout Tagout Procedure....................................................... 1-12
Pre-Steps Before Lockout Tagout.......................................................1-12
Lockout Tagout Power ........................................................................1-12
Lockout Tagout Air Supply ..................................................................1-13
Start Maintenance...............................................................................1-13
Post Maintenance Steps.....................................................................1-13
Zero-Energy to Start-Up .......................................................... 1-14
Getting Help from KVAL........................................................... 1-16
Kval Return and Warranty Policy............................................. 1-17
Send the Item .....................................................................................1-17
Acceptance of Return .........................................................................1-17
Refund Turnaround Time ....................................................................1-17
Kval Errors..........................................................................................1-17
Customer Errors .................................................................................1-18
Shipper Errors.....................................................................................1-18
Warranty Replacement Parts..............................................................1-18
How to Download the Service Application ............................... 1-19
Download Application .........................................................................1-19
Safety Sign-Off Sheet .............................................................. 1-22
A Note to the Operator........................................................................1-22
Chapter 2 Operation of the 994-X
About This Chapter.................................................................. 2-2
Summary of Operation..........................................................................2-2
The 994-X will:......................................................................................2-2
Quick Start ............................................................................... 2-3
Powering Operations for the 994-X ......................................... 2-5

Kval 994-X Operation Manual
Table of Contents
How to Power Up the 994-X .................................................................2-5
Home the 994-X....................................................................................2-6
How to Power Down the 994-X.............................................................2-6
Emergency Shutdown and Recovery ...................................................2-7
Description of User Interface Screens ..................................... 2-8
Screen Selection Menu Map.................................................................2-8
Machine Feed Back..............................................................................2-8
Controlling Access to User Screens .....................................................2-8
Menu Maps of the Operator Screens....................................... 2-9
About the Main Screen ............................................................ 2-11
About the Setup Screens......................................................... 2-15
About the Machine Calibration Screen ...............................................2-15
About the Setup Hinges 1-4 Screens .................................................2-17
About the Pre-Drill Screen..................................................................2-19
Pre Drill Setup Process.......................................................................2-20
About the Hopper Screen (Rotary) .....................................................2-21
About the Manual Operation Screens...................................... 2-22
About the Diagnostic Screen ................................................... 2-26
Option SB: About the CNC Back Section Operator Screens ... 2-27
Option SB: Main Menu Screen ...........................................................2-27
Option SB: Lock Calibration Screen ...................................................2-28
Option SB: Manual Screen .................................................................2-29
Option: AR-HQ2....................................................................... 2-30
Chapter 3 Calibration of 994-X
About Calibration ..................................................................... 3-2
Before you Calibrate.............................................................................3-2
Flow Chart of Calibration .....................................................................3-3
About the KVAL Calibration Routine ........................................ 3-4
Calibration Slot Drilling Specifications ..................................................3-5
Dimensions of a Calibration Cut ...........................................................3-5
Run the Calibration Routine..................................................... 3-6
Select Calibration..................................................................................3-6
Select Door Parameters .......................................................................3-6
Load the Door and Start the Cut...........................................................3-6
Check Specifications of the Front Section............................... 3-7
Enter a Positive or Negative Number? .................................................3-7
General Instructions to Adjust Parameters ...........................................3-8

Table of Contents
Kval 994-X Operation Manual
Step 1: Hinge Carriage Calibration.......................................................3-9
Step 2: Router Calibrations.................................................................3-12
Step 3: Pre-Drill Calibration ................................................................3-13
Step 4: (Option CH) Chisel Calibration...............................................3-15
Calibration of the Back Section................................................ 3-17
Lock Location Calibration ...................................................................3-17
Fast and Slow Lock Plate Timing........................................................3-18
Option SB: CNC Back Section Calibration .........................................3-19
Chapter 4 Tour of the 994-X
Operator’s Tour ........................................................................ 4-2
Options Available..................................................................................4-2
The 994-X will:......................................................................................4-2
Machine Component Terms..................................................... 4-3
Overview of Machine ............................................................... 4-4
994-X with Standard Hoppers...............................................................4-4
994-X with RTS Hoppers ......................................................................4-5
About the RTS Rotary Hopper..............................................................4-6
Basic Operation of the RTS ..................................................................4-7
Operator Controls .................................................................... 4-8
Operator’s Station.................................................................................4-8
Machine Control....................................................................................4-9
Door/Jamb Foot Pedal........................................................................4-10
About the In-Feed Section....................................................... 4-11
Door Stops..........................................................................................4-12
Setting Jamb Stop and Jamb Height ..................................................4-12
About the Front Section ........................................................... 4-13
About the Hinge Carriage ........................................................ 4-14
Option CR: Counter Rotate Router.....................................................4-15
Option CH: Added Chisels..................................................................4-16
About the Six/Eight Shooter System........................................ 4-17
Option K: Eight Shooter......................................................................4-18
About the Six/Eight Shooter Controls .................................................4-19
About the Hopper..................................................................... 4-20
Driver Assembly..................................................................................4-22
Option: Quick Change Knuckle Assembly ..........................................4-23
About the Over-Head Track ..................................................... 4-24
About the Back Section: .......................................................... 4-25

Kval 994-X Operation Manual
Table of Contents
Front View of Rear Section.................................................................4-25
Back View of Rear Section ................................................................4-26
Option SB: Back View of Rear Section...............................................4-27
Option BC: Ball Catch Motors.............................................................4-28
About the Out-Feed Section .................................................... 4-29
Option O: Air Blow Off.........................................................................4-30
Option IL: Left Hand / Right Hand Door Indicator...............................4-30
About the Electrical Panels...................................................... 4-31
Main Electrical Panel ..........................................................................4-31
High Frequency Panel ........................................................................4-32
Description of the Six Light Panel ........................................... 4-33
About Sensors ......................................................................... 4-34
Option: Checking Screw Delivery ............................................ 4-35
Option ND: Auto Narrow Door ................................................. 4-36
Option N: Weather Strip Brackets............................................ 4-37
Option SJ: Securing Split Jambs ............................................. 4-38
Option: Checking Screw Delivery ............................................ 4-39
Addendum (7’ 6” Door Stop).................................................... 4-40
Main Screen........................................................................................4-41
Calibration Screen ..............................................................................4-41

1-1
CHAPTER 1 Introduction to the 994-X System
This chapter provides an overview of the KVAL 994-X 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 994-X
System
This section provides an overview of the 994-X.
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 1-7
Zero-Energy to Start-Up Procedure to power up your machine for the first
time.
page 1-14
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 specifi-
cation plate tor provide to KVAL, service center
hours, and return procedures
page 1-16
Safety Sign-Off Sheet A record to track operators that are trained on the
machine.
page 1-22

Overview of the 994-X Door Hanging System
KVAL 994-X Operation Manual
1-2
Overview of the 994-X Door Hanging System
KVAL's 994-X offers a high-speed pre-hanging line with the additional flexibility of servo con-
trolled hinge routing sections. This includes high frequency spindles and programmable point to
point pre-drilling.
The 994-X is designed for both interior, exterior doors and jambs. It will accommodate 1-3/8" and
1-3/4" thick doors with a minimum width of 18" and a maximum width of 42”. Door lengths of 6'
8" or 8' 0" can both be machined. Hinge locations automatically shift between two pre-determined
factory set locations to accommodate both three hinge pockets (6’-8”) and four hinge pockets (8’).
Changeover does however require manual repositioning of the jamb clamp fixtures but can easily
be accomplished in under two minutes without the use of tools.
The door is power-fed into the machine and clamped into position. After the hinges are attached,
and machining is finished, the door and jamb automatically is off-feed as the next door enters the
machine
Hinge routing sections are completely servo controlled for pocket height, width, and depth. Each
hinge routing section is equipped with two 1-1/2 HP High Frequency spindle motors, one for rout-
ing and one for pre drilling on both the door and jamb. Servo motors allow the hinge router to
accelerate out of and decelerate into hinge corners eliminating over travel. Changeover from 3-1/
2” to 4” hinges is accomplished by selecting the desired size on the touch-screen.Our Point to
Point Pre-Drill system can be programmed to drill all common hinge patterns automatically.
Additionally, the use of servo motors allows you to machine both 1/4” and 5/8” radius corners
without changing out tooling.
Hinges may be attached manually or with the optional Six-Shooter to install 3-1/2" X 3-1/2"
hinges, or the optional Eight-Shooter for attaching 4" X 4" hinges while the door and jamb remain
clamped in position. Door-to-door productivity, including hinge mounting, is typically 35-55 sec-
onds. However, this varies depending on the operator and material flow.
The lock machining assembly will be positioned with a single servo driven ball screw. This is
controlled by the touch screen, and will allow settings for standard lock and dead bolt locations
based on the lock bore location. A third dead bolt bore may easily be added by entering the posi-
tion on the touch screen. The servo driven system will automatically position the lock boring
assembly when the door hand is changed. Lock detailing includes 2-1/8” face boring with push
button change over between 2-3/8” and 2-3/4” back sets; 1” bolt drill and face plate routing. Face
plate routing will be accomplished with a 1-1/2 hp Hi-Frequency spindle motor.
The 994-X will accommodate doors with raised molding one or both sides up to 3/4" high, and a
minimum of 4" between the raised molding and the edge of the door.
This machine is equipped with a solid state touch screen that replaces many of the mechanical
switches for the machine functions. The touch screen also includes the capability to view the sta-
tus of the various photo eyes and switches for quick diagnosis when needed, without having to
open the electrical panel or for the operator to leave his work station. The Touch Screen logic also
includes management functions such as Daily and Lifetime Totals.

Overview of the 994-X Door Hanging System
1-3
KVAL 994-X Operation Manual
About the Six Shooter
The Six-Shooter screw gun will attach 3-1/2" X 3-1/2" hinges to the door and jamb, # 9 X 3/4"
long flat head screws are automatically sorted and fed, six at a time, to the screw gun. The opera-
tor manually places the hinge onto the magnetic indexing fixture and then rolls and pivots the Six
Shooter into an "H" block at each hinge location to attach the hinges. Pressing the 'Reset' switch
then raises the Six Shooter and feeds a set of six screws for the attachment of the next hinge.
The Six Shooter, which is supported on ball bearing equipped steel wheels and is mounted on an
overhead track. The track and the Six Shooter are precisely aligned to ensure the hinge is properly
position into the pocket at each hinge location.
Available Options
For detailed information about available options, please contact our KVAL Sales and Service
department.
Option Title Description
Option A Six Shooter Gun for 3-1/2'' X
3-1/2''
To attach 3-1/2" X 3-1/2" hinges to the door and jamb,
No. 9 by 3/4" long flat head screws are automatically
sorted and fed, six at a time, to the screw gun. Operator
manually places the hinge onto the magnetic indexing fix-
ture and then rolls and pivots the Six Shooter into an "H"
block at each hinge location to attach the hinges. Press-
ing the 'Reset' switch then raises the Six Shooter and
feeds a set of six screws for the attachment of the next
hinge.
NOTE: Requires Option D: Pre-Drill System for Six
Shooter.
The Six Shooter, which is supported on ball bearing
equipped steel wheels, is mounted on an overhead track
that is precisely aligned to ensure the hinge is properly
position into the pocket at each hinge location.
Option
AC:
Metal Door Sensing Proximity
Switch
Allows operator to do the edge prep on a steel door with-
out accidentally doing a face bore into the door.
RT-FX Single Head machine with
the Rotary Hopper stand. The
Rotary option allows kind change of
screw type with preloaded screws.

Overview of the 994-X Door Hanging System
KVAL 994-X Operation Manual
1-4
Option
BC
Ball Catch Drills Drill assemblies are mounted onto the lock boring section
for drilling left hand and right hand doors for drive-in ball
catches. When selected the proper drill automatically piv-
ots in to drill into the top of the door. Note, minimum door
width for drilling is 18".
Option
CH
Corner Square Chisels Corner Square Option adds automatic corner squaring to
the hinge routing sequence in both the door and jamb.
Option includes two chisel mounting blocks per head,
each one containing two chisels. As one chisel is operat-
ing, the inactive chisel is in the reveal between the door
and jamb. For instance, when you are squaring the upper
right corner in the jamb, the lower right chisel will be in
the reveal. When the lower right chisel is squaring the
lower right corner in the door, the upper right chisels in
the reveal. Although two chisels are paired together in
one mounting block, each one is independently cali-
brated for vertical and horizontal travel as well as depth.
Option
CR
Counter Rotating Routers The standard 994X relies on automatic chip-out blocks
clamped between door and jamb to protect the door face
and jamb edges from chipping during hinge routing. This
option eliminates the chip-out blocks by adding four extra
routers to the hinge detailing section with left hand rota-
tion. As hinge pockets are routed, the left hand rotating
routing tool is used to minimize chipping of the door face
or jamb edge.
Option E Two-Stage Drilling Allows changeover for two different face bore sizes with a
selection on the control panel.
Customer to specify 1-1/2” or 1-5/8” for dead bolt face
bore when ordering. Standard lock boring bit is 2/1/8".
Option IL Door Hand Indicator Light Light will be mounted on the out-feed end of the 990-F4
that can be seen by the 700-C Assembly Table operator.
The light will be on when the door in the 994-X is being
machined as a right hand door and off for a left hand
door.
Option K Eight-Shooter Screw Gun for
4" X 4" Hinge
To attach 4" X 4" hinges to the door and jamb, No. 10 by
3/4" long flat head screws are automatically sorted and
fed, eight (8) at a time, to the screw gun. Operator manu-
ally places the hinge onto the magnetic indexing fixture
and then rolls and pivots the Eight Shooter into an "H"
block at each hinge location to attach the hinges. Press-
ing the 'Reset' switch then raises the Eight Shooter and
feeds a set of eight (8) screws for the attachment of the
next hinge.
Option O Door Blow-Off System Air blow-off tube cleans dust and chips from top of door
as it feeds out of the 994-X.
Option N Weatherstrip Retaining
Brackets
Isolates Weather Strips during the routing process. A protective bar
across top of H block keeps the strip up and away from the routers.
Option Title Description

Overview of the 994-X Door Hanging System
1-5
KVAL 994-X Operation Manual
Option
SB
Servo Backsection with Cor-
ner Squaring
The 994-X system combines very high quality hardware
detailing, with high speed productivity. Unique features
include computer controlled ball screw movements for all
router and chisels, complete with square lock face plates.
Backsection will have the ability to machine a face plate
at both "0" and "3" degree. Operator can select widths
from 1" to 1-1/4" wide and up to 2-3/4" in length.
Option
R1
Zero & Three Degree Hinge
Routing
Price includes PLC logic and controls to allow front hinge
routing section to rout on either a 0 degree or 3 degree
angle.
Hinges will be flush mounted when installed on doors
with either square edge or 3 degree bevel on hinge side
Option
UH
Top Hinge Dimension Differ-
ent for 6'-8" and 8'-0" Door
In-feed door and jamb stops will be movable. Door stop
will be cylinder actuated.
NOTE: Specifications for hinge locations must be pro-
vided in order to prepare quotation.
Option
W
Hinge Stops for 6'8", 7'0" &
8'0" Doors
This option is limited to certain hinge pocket locations.
Hinge location specifications need to be submitted in
order to determine if they can be accommodated with the
994-X.
Option Z Screw-Changing Hopper for
Six Shooter
Screw-changing hopper for changing screw colors.
Option
Z1
Quick-Change Hopper for
Eight Shooter
Screw changing hopper for Eight Shooter allows for rapid
change of screw colors.
Quick Change Knuckle Hinge Switch located on the Eight Shooter hinge applicator
which provides the ability to switch from a standard (nar-
row barrel) knuckle hinge to a wide spring-knuckle hinge.
Changeover time between knuckle sizes is 1 second.
Narrow Door Support Supports doors between 12" - 16”
Structure utilizes air cylinders and 7 pairs of industrial
wheels for support - mechanism is automatically put in
and out of position via a selection
Split Jamb Staplers Two 1/4" crown staple guns are mounted onto the jamb
clamp brackets. While clamped in the machine, staples
will be driven into the back side of the split jamb to keep
the male and female together.
The staple guns are fired with a single valve that is inter-
locked with a safety switch to disable the staple guns
unless there is a jamb clamped in the machine.
Two staple guns with remote fires are required and are
not included in the price of the option.
Option Title Description

About this Manual
KVAL 994-X Operation Manual
1-6
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 Interface Descriptions of how to power machine
line, and operator interface user screens.
Chapter 3 Calibration Description of the Calibration routines.
Chapter 4 Tour of the Machine Descriptions of the mechanical assemblies
on the machine
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!
1-7
KVAL 994-X 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 1-22.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that provide
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 994-X Operation Manual
1-8
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 1-12.
Compressed Air

Safety First!
1-9
KVAL 994-X 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 994-X Operation Manual
1-10
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
1-11
KVAL 994-X 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 994-X Operation Manual
1-12
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