Kval 990-H User manual

Innovation, Quality & Honesty
Service Manual
Published: 2/2/15
990-H Pre-Hanging Door System

KVAL 990-H Service 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: 137-SRVDOC_990H-V1
The 990-H Pre-Hanging Door 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 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:
6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]

KVAL 990-H Service Manual
KVAL 990-H Service 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-H Service Manual

KVAL 990-H Service Manual
Table of Contents
Chapter 1 Introduction to the 990-H Door Hanging System
Chapter 1 at a Glance.............................................................. 1-1
Overview of the 990-HDoor Hanging System......................... 1-2
About this Manual.................................................................................1-2
Safety First!.............................................................................. 1-3
Safety Sheet Sign-Off Sheet.................................................................1-3
Safety Terminology of Labels................................................................1-3
Safety Guidelines..................................................................................1-3
Lockout Tagout Procedure....................................................................1-7
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9
Zero-Energy to Start-Up........................................................... 1-10
Zero-Energy State to Start-Up to Operating State ..............................1-10
Getting Help from KVAL........................................................... 1-12
On-Line Help.......................................................................................1-12
Product Return Procedure..................................................................1-12
Safety Sign-Off Sheet.............................................................. 1-14
A Note to the Operator:.......................................................................1-14
Chapter 2 Maintenance of the 990-H
Operator’s Tour........................................................................ 2-2
990-H Machine Tour .............................................................................2-3
Maintenance Schedule............................................................ 2-4
Daily......................................................................................................2-4
Weekly..................................................................................................2-5
Six Month Checkups.............................................................................2-5
Lubrication Requirements........................................................ 2-6
Linear Bearings, Flange Bearing, and Pillow Blocks............................2-6
Gear Motor Lubrication Requirements..................................................2-7
Ball Screws...........................................................................................2-7
Description of Air Input System ............................................................2-7
Adjusting the Air Line Lubricator ..........................................................2-8
Priming the Air Line Lubricator .............................................................2-8
Lubrication Points on the 990-H .............................................. 2-9
Feed System Lube Points.....................................................................2-9
Screw Driver Lube Points...................................................................2-10

990-H Door Hanging System
Back Section Lube Points...................................................................2-11
Head Lube Points...............................................................................2-12
Replacing Bits.......................................................................... 2-13
Replacing Bits in the Front Section ....................................................2-13
How to Access to Bit Assemblies .......................................................2-14
Remove and Replace the Screwdriver Bits........................................2-16
Mechanical set up of the 990-H............................................... 2-18
Back Section.......................................................................................2-19
Chapter 3 Trouble Shooting of the 990-H
Network System Overview....................................................... 3-2
Connections to Servo Drives................................................................3-3
High Frequency Panel Node Connections............................................3-4
Frame Node Connections.....................................................................3-5
Back Section Node...............................................................................3-6
Screw Driver Nodes 1-3........................................................................3-7
About Sensors......................................................................... 3-9
Using Sensors to Trouble Shoot...........................................................3-9
Location of Sensors on 990-H............................................................3-10
Troubleshooting Electrical Problems ....................................... 3-13
If the Power Stops During Normal Operation......................................3-13
Troubleshooting with the Status Light Panel.......................................3-14
Troubleshooting the Air Cylinders............................................ 3-18
Adjusting Cylinder Extension Speed:..................................................3-20
Adjusting Cylinder Retraction Speed:.................................................3-20

1-1
CHAPTER 1 Introduction to the 990-H Door Hanging
System
This chapter provides an overview of the KVAL 990-H Door Hanging System and important
safety information to follow when operating the machine.
Chapter 1 at a Glance
Chapter 1 at a Glance ....................................................................................... 1-1
Overview of the 990-H Door Hanging System .............................................. 1-2
About this Manual ..................................................................................... 1-2
Safety First! ...................................................................................................... 1-3
Safety Sheet Sign-Off Sheet ...................................................................... 1-3
Safety Terminology of Labels .................................................................... 1-3
Safety Guidelines ....................................................................................... 1-3
Lockout Tagout Procedure ......................................................................... 1-7
Follow the P-R-O-P-E-R lockout rule of thumb. ....................................... 1-9
Zero-Energy to Start-Up ................................................................................ 1-10
Zero-Energy State to Start-Up to Operating State ................................... 1-10
Getting Help from Kval ................................................................................. 1-12
On-Line Help ........................................................................................... 1-12
Product Return Procedure ........................................................................ 1-12
Safety Sign-Off Sheet .................................................................................... 1-14
A Note to the Operator: ........................................................................... 1-14

Overview of the 990-H Door Hanging System
1-2 KVAL 990-H Service Manual
Overview of the 990-H Door Hanging System
KVAL's 990-H is the fastest and most productive pre-hanging system available in the industry.
The 990-H will rout and chisel a door and jamb for three hinges, drill pilot holes for the hinge
screws, mortise for the lock, and apply three hinges. This machine is generally used in conjunc-
tion with the ON-2012 for in-feed and out-feed operations. 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. The 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.
About this Manual
This manual is one of two manuals. The set includes this Operation Manual and Service Manual.
The Operation Manual is directed toward operators of the machine. It includes identification of
machine assemblies, power-up and power-down steps, operation and using the user interface.
The Service Manual is directed toward qualified service technicians. It includes maintenance and
troubleshooting information.
TABLE 1.
Title Part Number
990H Operation Manual 137-OPDOC_990H
990H Service Manual 137-SRVDOC_999H

Safety First!
1-3
KVAL 990-H Service Manual
Safety First!
The 990-H Door Hanging System is a powerful electro-
mechanical motion control system. You should test your
motion system for safety under all potential conditions. Fail-
ure to do so can result in damage to equipment and/or seri-
ous injury to personnel.
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 1-14.
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 the 990-H system, follow the guidelines
below to help ensure the safety of equipment and 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

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 1-7.
Compressed Air
Safety First!
1-4 KVAL 990-H 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 elec-
trical and air pressure systems. This should be
done in accordance with applicable state and/
or federal code requirements.
Before Conducting Maintenance
Safety First!
1-5
KVAL 990-H Service Manual

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.
Safety First!
1-6 KVAL 990-H Service Manual

Safety First!
1-7
KVAL 990-H Service Manual
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 the 990-H 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.
To Lockout the 990-H
1. Assess the equipment to fully understand all energy sources (multiple electrical sup-
plies, air supply and pressure, spring tension, weight shifts, etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration of the shut-
down.
3. Obtain locks, keys, and tags from your employer’s lockout center.
4. Disconnect power:
a.Turn the disconnect switches on the main electrical panel to the OFF position.
Then pull out the red tab and place a padlock through the hole. Place your tag
on the padlock, as per the tagout guidelines below. (see illustration below).
When multiple people are
working on the machine, each
person needs to have a lock on
the handle in the extra holes
provided.
b.Turn the disconnect switch on the larger high-frequency panel to the OFF
position. Then pull out the red tab and place a padlock through the hole. Place
your tag on the padlock, as per the tagout guidelines below.

Safety First!
1-8 KVAL 990-H Service Manual
5. Turn the main air valve to the OFF position and place a padlock through the hole
(see illustration below).
NOTE: Place your tag on the padlock, as per the tagout guidelines below.
6. Once the locks and tags are in place and all personnel are clear, attempt to operate
the machine to ensure equipment will not operate.
7. Maintenance or repairs may now be 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.
8. 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.
9. The lock and tag can now be removed (only by the person(s) who placed them), and
the machine can be re-energized.
10. The tags must be destroyed and the locks and keys returned to the lockout center.
Lockout-Tagout Guidelines
• Place a tag on all padlocks. On a 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, then each additional person places a
lock and tag on each disconnect.
• Only each operator may remove their own
lock and tag.

Safety First!
1-9
KVAL 990-H Service Manual
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

Zero-Energy to Start-Up
1-10 KVAL 990-H Service Manual
Zero-Energy to Start-Up
Zero-Energy State to Start-Up to Operating State
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 “Contacting KVAL” on
page 1-2.
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

Zero-Energy to Start-Up
1-11
KVAL 990-H Service Manual
may use a gang box or other system to ensure that locks are secure and not removed
without authorization.
Remember, lockout/tagout procedures work because you are the only one with the key
to your lock. Proper lockout/tagout can save lives, limbs, and money. Help make your
work environment safe for you and your fellow workers. Be sure to follow the P-R-O-
P-E-R lockout/tagout procedures, and that those around you do also.
Close the Cage Gate
Verify all cage gates are securely closed. Ensure all safety protocols are in effect.

Getting Help from KVAL
1-12 KVAL 990-H Service Manual
Getting Help from KVAL
Before you seek help, first try the troubleshooting procedures. Follow the procedures below.
If you are unable to resolve the problem:
1. Locate the machine’s Specification Plate and record the serial number, 3 phase
volts, electrical print number, and air print number.
Serial Number
3 phase volts
Electrical Print
Air Print
2. Contact our customer support team:
• In the U.S and Canada, call [phone] or fax [phone]
• Outside the U.S. and Canada, call [phone] or fax [phone]
• Email address is [email protected]
• Hours: 6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday
6:30 AM to 1:30 PM Pacific Standard Time, Friday
On-Line Help
On machines with a Beckhoff®PLC and an internet connection, our service team are able to con-
nect, run, and troubleshoot your machine. Ask about this procedure when calling are service
team.See Chapter 3 “System IT Administration” on page 3-1, for more information.
Product Return Procedure
If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure
below to return the machine or part.
Note: Non-Warranty returns are subject to a 15% restocking charge.
1. Obtain the packing slip and/or invoice numbers of the defective unit, and secure a
purchase order number to cover repair costs in the event the unit is determined to be
out of warranty.

Getting Help from KVAL
1-13
KVAL 990-H Service Manual
2. Reason for return: Before you return the unit, have someone from your organization
with a technical understanding of the machine and its application include answers to
the following questions:
• What is the extent of the failure/reason for return? What are the relevant error mes-
sages or error codes?
• How long did it operate?
• Did any other items fail at the same time?
• What was happening when the unit failed (e.g., installing the unit, cycling power,
starting other equipment, etc.)?
• How was the product configured (in detail)?
• Which, if any, cables were modified and how?
• With what equipment is the unit interfaced?
• What was the application?
• What was the system environment (temperature, spacing, contaminants, etc.)?
3. Call Kval customer support for a Return Material Authorization (RMA). When you
call:
• Have the packing slip or invoice numbers available.
• Have the documented reason for return available.
4. Send the merchandise back to Kval.
• Make sure the item(s) you are returning are securely packaged and well protected
from shipping damage
• Include the packing slip or invoice numbers.
• Include the documented reason for return.
• Include the RMA number with the parts package.

Safety Sign-Off Sheet
1-14 KVAL 990-H Service Manual
Safety Sign-Off Sheet
Machine Model Number:_____________________________
A Note to the Operator:
This machine can help you be highly productive only if you understand how to use it properly and
follow the safe operating practices described in this document and the machine’s manual. If you
do not understand the machine’s proper operation or ignore the safe operating practices, this
machine can hurt or kill you. It’s in your best interest to safely and properly operate this machine.
Personnel Safety Concerns:
• I have been properly trained in the operation of this machine.
• I will always wear ear protection when operating this machine.
• I will always wear eye protection when operating this machine.
• I will never wear lose clothing or gloves when operating this machine.
• I will watch out for other people. Make sure everyone is clear of this machine
before operation.
• I will always follow my company’s safety procedures. I have read and understand
these guidelines.
Machine Safety Concerns:
• I have been given a tour of the machine and understand all the safety labels, E-
Stops and the actions to take in case of an emergency.
• I will make sure all guards are in place before operation
• I will turn off the compressed air, before loading hardware (staples, screws, etc)
• I will turn off the electrical power, for setup
• If the machine should operate in an unexpected manner stop production I will
immediately and notify a manager, a supervisor, or a qualified service technician.
I have read and understand this document and agree to operate this machine in a safe man-
ner as described above.
Employee
Name (print):___________________ Signature: __________________ Date:____/____/____
Supervisor/Safety Officer/Trainer
Name (print):__________________Signature: __________________ Date:____/____/___
Note: It is recommended you make a copy of this sheet for new operators. If a copy is
needed, you may download a PDF at the KVAL website (http://
www.kvalinc.com). You may also contact our Service Department at (800) 553-
5825 or email at [email protected].