Kval 990-HQ Operating instructions

Innovation, Quality & Honesty

Operation Manual

:August 15, 2019

990-HQ Pre-Hanging Door System

990-HQ Operations Manual

KVAL 990-HQ 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 (800) 553-5825 or fax (707) 762-0485. Outside the

U.S. and Canada, call (707) 762-7367.

Manual Part Number: DOC_187_1_OP

The 990-HQ Pre-Hanging Door System is a trademark of Kval Incorporated.

Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed

by Beckhoff Automation GmbH

Windows CE® is a registered trademark of Microsoft Corporation.

All other products are trademarks or registered trademarks of their respective holders,

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 (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• 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-HQ 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-HQ Operation Manual

Table of Contents

KVAL 990-HQ Operation Manual

Chapter 1 Introduction to the 990-HQ

Chapter 1 at a Glance.............................................................. 1-1

About this Manual .................................................................... 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-HQ

The 990-HQ Process Summary............................................... 2-2

Machine Orientation..............................................................................2-2

Typical Production Line Layout.............................................................2-2

Top View of Machine................................................................2-3

About the Operator Station and Front Section Controls .......... 2-4

About the Foot Pedal and Control Box .................................................2-5

Control Box..........................................................................................2-5

Hinges Loaded Button (Status Light)....................................................2-6

About the In-Feed Section ....................................................... 2-7

About the Front Section ........................................................... 2-8

KVAL 990-HQ Operation Manual

Table of Contents

About the Hinge Heads.........................................................................2-9

About the Eight Shooter System.............................................. 2-10

About the Hopper................................................................................2-10

Hopper Process..................................................................................2-11

About the 8 Shooter Assembly ...........................................................2-13

About the Driver Assembly .................................................................2-14

About the Back Section ........................................................... 2-15

Front and Rear Views of the Back Section .........................................2-16

About the Out-Feed ................................................................. 2-17

About the Electrical Panels...................................................... 2-18

Electrical Panel Option: Servo Box 2..................................................2-19

Description of the Six Light Panel ........................................... 2-20

Machine Start Summary .......................................................... 2-21

If Processing a Fourth Hinge ..............................................................2-23

Powering Operations for the 990-HQ ...................................... 2-24

How to Power Up the 990-HQ ............................................................2-24

Home the 990-HQ...............................................................................2-25

How to Power Down the 990-HQ........................................................2-25

Safety Controls ........................................................................ 2-26

Emergency Shutdown and Recovery .................................................2-26

To Resume Normal Operation after an E-Stop ...................................2-26

Air Brake on 990-HQ Eight Shooter....................................................2-26

Summary of the Interface ........................................................ 2-28

Machine Control and Calibration Screens ..........................................2-28

Machine Feed Back ................................................................. 2-30

Controlling Access to User Screens ...................................................2-30

Main Screen............................................................................. 2-31

Main Screen Descriptions...................................................................2-31

Manual Operation .................................................................... 2-36

Manual Jog Screen.............................................................................2-36

About Calibration ..................................................................... 2-40

Before you Calibrate ...........................................................................2-40

Flow Chart of Calibration ...................................................................2-41

About the Entering Data into the Setup Screens ..................... 2-42

How to Enter Calibration Data ............................................................2-42

Enter a Positive or Negative Number? ...............................................2-43

Servo Motor Drive Assembly Locations................................... 2-44

Setup Screen ........................................................................... 2-45

Table of Contents

KVAL 990-HQ Operation Manual

Main Calibration Screen Descriptions.................................................2-45

Setup Hinges 1-3 Screens....................................................... 2-49

Calibration Slot ...................................................................................2-49

Dimensions of a Calibration Cut .........................................................2-49

Screen Details ....................................................................................2-50

Chisel Calibration..................................................................... 2-54

About the Pre-Drill Screen ....................................................... 2-55

Entering Pre-Drill Pattern Data ...........................................................2-55

Example of Data Input ........................................................................2-56

Diagnostic Screen.................................................................... 2-57

Status of I/O and E-Stops Screen ............................................ 2-58

Appendix: Machine Component Terms.................................... 2-60

KVAL 990-HQ Operation Manual

Table of Contents

Chapter 1 at a Glance

1-1

990-HQ Operation Manual

CHAPTER 1 Introduction to the 990-HQ

This chapter provides an overview of the KVAL 990-HQ 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

System

This section provides an overview of the 990-HQ. It

includes a general description and a table of available

options

page 1-2

Safety First! IMPORTANT safety information is described in this sec-

tion

page 1-5

Lockout Tagout IMPORTANT: Procedure to Lockout Tagout equipment

when it is being serviced.

page 1-10

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

How to Download the

Service Application

Procedure to download an interactive application to

allow Service Technician to control your machine and

help troubleshoot.

page 1-16

Safety Sign-Off Sheet A record to track operators that are trained on the

machine.

page 1-19

About this Manual

1-2

990-HQ Operation Manual

About this Manual

The 990-HQ entry door pre-hanging system produces machined doors with one or two cylindrical

locks and either three or four hinges attached to the door edge and hinge jamb. Hinges can be

mounted with or without hinge pins inserted.

In operation, the machine automatically adjusts to incoming door width and positions the door

against the appropriate index point for selected door swing and length, then clamps. Simultane-

ously an operator inserts a blank hinge jamb and clamps it in place with an electric foot-pedal.

Pressing a button starts the hinge routing and lock detailing sequence which takes less than 20

seconds including drilling screw holes for hinges as well as routing lock face plates. Afterwards

three 8 shooter screw guns gang feed screws and fasten three hinges. Overall cycle for a three

hinge doors produced one after another is less than 40 seconds even with two locks.

Doors requiring four hinges are processed with an extra step. After completion of the three hinge

sequence described above, the left or right routing head (depending on swing) will unclamp from

the door and jamb, then shift sideways to re-clamp and process a fourth hinge pocket. The direc-

tion of shift from the third hinge depends on door length, and will match Hume specifications of

approximately 100mm each direction. The gap between hinges is programmable. One eight

shooter screw-driving head is used to fasten the fourth hinge, and the door is automatically fed out

of the machine. Overall door to door cycle for four hinge units is less than 70 seconds.

Design features:

Lock Detailing: Includes a servo driven ball screw and programming to automatically position

and process one or two cylinder locks during the machine sequence. The touch screen panel pro-

vides multiple standard lock layouts or custom locations from the numeric key pad. The lock

machining mechanism includes heavy duty drill motors mounted above and below the door to

eliminate chipping door faces, a separate side drill for latch holes, and high frequency spindle

router for lock face plates.

Hinge Detailing: Three hinge heads, each with separate XYZ motion control to precisely rout and

drill hinge pockets in door and jamb. Each head has standard rotation spindle, reverse rotation

spindle, single point drill spindle and for corner square chisels. Motions are smooth and precise

with programming selected at the touch screen for a variety of hinge sizes and drill patterns,

including square hinges.

Hinge Locations: Each hinge head, jamb clamp fixture, door and jamb index stop and each screw-

driving heads is mounted on either 15mm or 25mm box bearings with ball screws and servo

motors to automatically adjust hinge locations to a variety of door and jamb sizes and positions

matching Hume specifications. Similar to lock locations, hinge layouts can be pre-programmed

and selected at the touch screen. The machine already includes 11 servo motor/ball screws for

lock and hinge processing. Adding programmable movements for machine adjustment adds 6

more: two for outside hinge heads, two for outside jamb clamps, two to adjust outside 8 shooters

to match heads.

Hinge attachment: three eight shooter screw guns are provided. Each unit is hydraulically driven

with ample power to drive screws even in hard-wood applications. Screws are fed eight a time

from an overhead sorting hopper down to the spring loaded guides. In operation, after placing a

About this Manual

1-3

990-HQ Operation Manual

hinge on the magnetic hinge blocks, pressing a button shifts the center and right guns laterally,

then all three guns travel downwards and index into “H” block fixtures at each hinge location, and

fasten the hinges simultaneously. A fourth hinge can be added afterwards as described earlier with

an extra hinge machining sequence. One hinge is placed on the appropriate screw-driving head

and sequenced to fasten the fourth hinge.

This machine is equipped with a solid state touch screen and industrial PC. The touch screen also

includes the capability to view the status of the various photo eyes and switches for quick diagno-

sis 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. When connected to the internet, the PC allows remote support and monitoring of machine

functions from Kval in Petaluma, CA.

Door and jamb clamp reference: The door will clamp downwards rather than upwards and the

jamb reference will be to jamb stop (top of H block not staging block for jamb edge). This pro-

vides a consistent dimension between jamb weather strip and door face when the door is closed.

Minor variations in door thickness will be seen instead between the jamb edge and door face – a

thin door for instance will be spaced inside the frame slightly. Removable spacers will be fabri-

cated to insert in the top of each “H” block to compensate for jambs with weather stripping, or for

jambs without weather stripping, and to reference jambs with 38mm backset for 35mm doors.

Note: spacers will need to be chamfered on outside "H" blocks to protect weather stripping during

shift for fourth hinge.

Door Details:

Maximum Door Height: 2700mm**

Minimum Door Height: 1980 mm

About this Manual

1-4

990-HQ Operation Manual

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

Calibration

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

990-HQ Operation Manual

Safety First!

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.

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 me if the danger is not avoided, it will cause death or serious injury.

• WARNING me if the warning is not heeded, it can cause death or serious injury.

• CAUTION me 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.

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 1-10.

Compressed Air

Safety First!

1-6

990-HQ 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!

1-7

990-HQ Operation 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!

1-8

990-HQ Operation Manual

Lockout-Tagout Guidelines

1-9

990-HQ 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

1-10

990-HQ Operation 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 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

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.

Lockout Tagout Power

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

990-HQ Operation Manual

Lockout Tagout Air Supply

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.

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.

Zero-Energy to Start-Up

1-12

990-HQ Operation Manual

Zero-Energy to Start-Up

Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of

safety.

Start-up Guidelines

The following guidelines below should be followed to start the equipment.

Inspect

The equipment must be inspected for proper adjustment before starting equipment.

Clean Up

All materials and debris must be cleaned up. Any combustible materials or old parts

used during repairs must be cleaned up and/or properly disposed of.

Replace Guards

Replace all equipment guards. If part of equipment cannot be properly adjusted after

start-up with guard on, contact the KVAL Service team. See “Getting Help from

KVAL” on page 1-14.

Check Controls

Confirm that all switches are in the “OFF” position. Please be advised that some com-

ponents of the machine may start automatically when energy is restored.

Remove Locks

Each operator must remove his or her own lock and tag. This will ensure that all oper-

ators are in a safe place when the equipment is started.

Perform Visual Checks

If the equipment is too large to see all around it, station personnel around the area and

sound the personnel alarm before starting the equipment. If your operation is more

complex, your company’s comprehensive safety procedure may involve additional

steps. You will need to ask your supervisor about these procedures. The company’s

lockout procedure should be posted at each machine. On larger or long-term mainte-

nance or installation projects, the company’s procedures must be explained to all new

operators and a copy of the company’s procedures should be posted on-site for the

duration of the work.

The Company’s procedures should also include provisions for safely handling shift

changes and changes in operators or new operators.Comprehensive lockout/tagout

may use a gang box or other system to ensure that locks are secure and not removed

without authorization.

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Kval 990-HQ Operating instructions

Kval 990-HQ Operating instructions

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