Kval 990-FX Owner's manual

Brand: Kval

Model: 990-FX

Type: Owner's manual

Innovation, Quality & Honesty

990FX Operational

Reference Manual

Published: March 28, 2007 REV. 1.2

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

Proprietary Notice

This document contains confidential and trade secret information, which is proprietary to Kval, Inc. (“Kval”), and is

protected by laws pertaining to such materials. This document, the information in this document, and all rights

thereto are the sole and exclusive property of Kval, are intended for use by customers and employees of Kval, and

are not to be copied, used, or disclosed to anyone, in whole or in part, without the express written permission of

Kval. 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.

KVAL 2007 and 990FX are trademarks of Kval, Incorporated.

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 Incorporated products, contact

the Customer Support Department

• http://www.kvalinc.com/customer_service.html (lists all the representatives, including email

addresses and phone numbers)

• 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: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Friday

Parts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday

(Other sales related inquiries: http://www.kvalinc.com/contact_us.html)

• Email: [email protected]

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

improvement to [email protected]om. (NOTE: This is not a way to get customer support. For that,

please refer to the Customer Service contact information above.)

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

Table of Contents

ABOUT THIS GUIDE.....................................................................................................................................................5

Audience.....................................................................................................................................................................5

How This Guide Is Organized...................................................................................................................................5

Related Publications..................................................................................................................................................5

Printed Documentation.................................................................................................................................5

CHAPTER 1: INTRODUCTION.....................................................................................................................................7

Uncrating the 990FX..................................................................................................................................................7

Receiving the 990FX ..........................................................................................................................................7

Uncrating Setup..................................................................................................................................................7

Tools Required: ............................................................................................................................................7

Uncrating Procedure..........................................................................................................................................7

Anchoring the 990FX.................................................................................................................................................8

Overview of the 990FX...............................................................................................................................................9

Operation.............................................................................................................................................................9

Safety First! ................................................................................................................................................................9

Lock-Out/Tag-Out Procedure..........................................................................................................................10

Lock and Tag-Out Guidelines.....................................................................................................................12

CHAPTER 2: SETTING UP THE 990FX .....................................................................................................................13

Front Section............................................................................................................................................................13

Setting Up Hinge Centers................................................................................................................................13

Preliminary Hinge Center Set-Up...............................................................................................................13

Positioning H-Blocks...................................................................................................................................13

Centering Routers Within the H-Block........................................................................................................13

Setting Up the Hinge Backset.........................................................................................................................14

Setting the Doorstops......................................................................................................................................14

Back Section.............................................................................................................................................................14

Setting Up Lock Height....................................................................................................................................15

Setting Up Lock Bore Backset........................................................................................................................15

If No Auto Backset on 990FX: Side Drill (Latch Hole).................................................................................16

Lock Bore Diameter .........................................................................................................................................16

Plate Width: Plate Router Vertical Travel ......................................................................................................16

Plate Router Depth...........................................................................................................................................16

Adjust Plate Router for Three-Degree Bevel Set .......................................................................................16

Adjust Plate Router from Three-Degree Bevel Set to Zero-Degree Bevel Set..........................................17

CHAPTER 3: AUTO RUN WALKTHROUGH..............................................................................................................19

General Operation....................................................................................................................................................19

Machine Orientation ................................................................................................................................................19

Back Section / Front Section ..........................................................................................................................19

Machine Components......................................................................................................................................19

Auto Run...................................................................................................................................................................20

Preliminary Setup.............................................................................................................................................20

Review of Safety Information......................................................................................................................20

Review of Machine Orientation Information ...............................................................................................20

Review of Safety Stickers on the 990FX....................................................................................................20

Safety Hooks ..............................................................................................................................................20

Auto Door/LH-RH........................................................................................................................................21

Emergency Stop.........................................................................................................................................21

Load Screws...............................................................................................................................................21

Powering On the 990FX...................................................................................................................................21

Control Transformer: ..................................................................................................................................21

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

Start ............................................................................................................................................................21

The Operator’s Station: Touchscreens..........................................................................................................21

Main Menu Touchscreen.................................................................................................................................21

Auto Run Touchscreen....................................................................................................................................22

Auto Feed...................................................................................................................................................22

Feed OFF ...................................................................................................................................................22

Auto Unclamp OFF/ON: .............................................................................................................................22

Auto Width OFF/ON ...................................................................................................................................22

Door Setup..................................................................................................................................................22

Door Setup Touchscreen ................................................................................................................................22

Bolt Drill ......................................................................................................................................................22

Lock Bore....................................................................................................................................................22

Faceplate....................................................................................................................................................23

Router/FP Continue Run............................................................................................................................23

Route Jamb ................................................................................................................................................23

Route Door .................................................................................................................................................23

Pre-Drill.......................................................................................................................................................23

Previous Menu............................................................................................................................................23

Screwdriver Setup Touchscreen....................................................................................................................23

Off...............................................................................................................................................................23

Left & Right.................................................................................................................................................23

All................................................................................................................................................................24

Previous Menu............................................................................................................................................24

Loading and Clamping the Jamb....................................................................................................................24

Loading the Hinges..........................................................................................................................................24

990FX Control Box...........................................................................................................................................24

Start Sequence.............................................................................................Error! Bookmark not defined.

Hinges Loaded............................................................................................................................................24

CHAPTER 4: TOUCHSCREENS.................................................................................................................................25

Touchscreen Walkthrough—Four Operational Touchscreens...........................................................................25

Main Menu Touchscreen.................................................................................................................................25

1. Auto Run Touchscreen................................................................................................................................25

1.1. Feed Off...............................................................................................................................................26

1.2 Auto Feed.............................................................................................................................................26

1.3 Feed Thru.............................................................................................................................................26

1.4 Machine OK/Machine Error..................................................................................................................26

1.5 Reset Error ...........................................................................................................................................26

1.6 Auto Unclamp OFF/ON ........................................................................................................................26

1.7 Door Clamp...........................................................................................................................................27

1.8 Door Stop..............................................................................................................................................27

1.9 Auto Width OFF/ON .............................................................................................................................27

1.10 Router/FP Continue Run....................................................................................................................27

1.11 Manual Run ........................................................................................................................................27

1.12 Screwdriver Setup..............................................................................................................................27

1.13 Door Setup..........................................................................................................................................27

1.14 Previous Menu....................................................................................................................................27

2. Manual Run Touchscreen ...........................................................................................................................27

2.1 Feed Mode: Auto/Feed Thru ................................................................................................................28

2.2 Jog REV................................................................................................................................................28

2.3 FAST/SLOW.........................................................................................................................................28

2.4 Jog FWD...............................................................................................................................................28

2.5 Auto Width OFF/ON .............................................................................................................................28

2.6 Jog OPEN.............................................................................................................................................29

2.7 Jog CLOSE...........................................................................................................................................29

2.8 Shift Router Out of Pocket....................................................................................................................29

2.9 Door Stop..............................................................................................................................................29

2.10 Clamp .................................................................................................................................................29

2.11 Burn Chipout.......................................................................................................................................29

2.12 Previous Menu....................................................................................................................................29

3. Door Setup Touchscreen ............................................................................................................................30

3.1 Faceplate Ext. Time..............................................................................................................................30

3.2 Bolt Drill ................................................................................................................................................30

3.3 Lock Bore..............................................................................................................................................30

3.4 LockBore Deep.....................................................................................................................................30

3.5 2 ¾”...................................................................................................................................................30

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

3.6 Faceplate..............................................................................................................................................30

3.7 Router/FP Continue Run......................................................................................................................31

3.8 Route Jamb ..........................................................................................................................................31

3.9 Route Door ...........................................................................................................................................31

3.10 Split Jamb Nailer ................................................................................................................................31

3.11 Pre-Drill OFF/ON................................................................................................................................31

3.12 Previous Menu....................................................................................................................................31

4.1 OFF.......................................................................................................................................................32

4.2 Left & Right...........................................................................................................................................32

4.3 ALL .......................................................................................................................................................32

4.4 OFF.......................................................................................................................................................32

4.5 Left........................................................................................................................................................32

4.6 Center...................................................................................................................................................32

4.7 Right .....................................................................................................................................................33

4.8 Clear Screws ........................................................................................................................................33

4.9 Blow Screws.........................................................................................................................................33

4.10 Screw Drop Off...................................................................................................................................33

4.11 Shift Screwdrivers...............................................................................................................................33

4.12 Reload Screws ...................................................................................................................................33

4.13 Previous Menu....................................................................................................................................33

990FX Control Box...........................................................................................................................................33

Start Sequence...........................................................................................................................................33

Auto Door/LH-RH........................................................................................................................................34

Hinges Loaded............................................................................................................................................34

Unclamp......................................................................................................................................................34

Emergency Stop.........................................................................................................................................34

Operating the 990FX................................................................................................................................................34

CHAPTER 5: MAINTENANCE....................................................................................................................................37

Maintenance Schedule for 990FX...........................................................................................................................37

Daily...................................................................................................................................................................37

Weekly...............................................................................................................................................................37

Monthly..............................................................................................................................................................37

May and December Check Ups.......................................................................................................................37

Lubrication Requirements ......................................................................................................................................38

Linear Bearings................................................................................................................................................38

Flange Bearing .................................................................................................................................................38

Lubricate special high speed bearings..........................................................................................................38

Perske High Frequency Motors......................................................................................................................38

Approved Lubrication Products.....................................................................................................................38

Lubricator Adjustments...................................................................................................................................39

Gear Motor Lubrication Requirements..........................................................................................................39

Priming the Lubricator.....................................................................................................................................39

Replacing Screwdriver Bits ....................................................................................................................................40

CHAPTER 6: GENERAL OPERATIONAL TROUBLESHOOTING.............................................................................41

Hinge Dropped During Application........................................................................................................................41

Hinge Dropped Behind Router Head During Application....................................................................................41

APPENDIX A: LOCATIONS FOR PHOTO EYES, SENSORS, LIMIT SWITCHES, AND INPUT AND OUTPUT

NODES ........................................................................................................................................................................45

Troubleshooting Touchscreens.............................................................................................................................45

990FX Operational Reference Manual, Rev. 1.2, 2007 5

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

About This Guide

This guide describes how to operate the 990FX, a numerically controlled door cut-out system.

Audience

This guide is written for machine operators and factory technicians who are responsible for

operating the 990FX machine.

How This Guide Is Organized

This guide is organized as follows:

 Chapter 1: “Introduction”

Provides a brief introduction to 990FX and identifies safety precautions and procedures.

 Chapter 2: “Basic Operation”

Provides and introduction to the operator features, and provides procedures for accomplishing

basic operator tasks.

Related Publications

Printed Documentation

In addition to this Operational Reference Manual, the following documents are provided with the

product.

Document Description Location (in addition to online)

990FX Unpack

and Installation

Guide

Provides guidelines and

procedures for site prep,

unpacking, positioning, and

installing the 990FX system

• Top-most item inside the “Open Me

First” box, found on the out-feed end

of the 990FX machine (as shipped)

• System Reference binder

System

Schematics Complete electrical schematics

for the 990FX system System Reference binder (look for the

separate tab for this item)

990FX Operational Reference Manual, Rev. 1.2, 2007 7

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Chapter 1: Introduction

This chapter provides uncrating and anchoring information for the 990FX, a description of the

990FX machine, and safety guidelines that you should follow to ensure safety to personnel and

equipment.

Uncrating the 990FX

Receiving the 990FX

The 990FX is crated before shipping to protect the machine from damage that might occur while

in transit to your location. The vast majority of the time our machines arrive intact, but

unfortunately, sometimes that’s not the case. When you receive your machine, review it for

damage, missing bolts, or part box(es) that have shaken loose in the truck.

Uncrating Setup

The machine is shipped with all the moving assemblies having either been taped, blocked, banded,

or restrained with painted set collars to prevent any movement during shipping. Before beginning

set-up procedures, ensure that all shipping materials have been removed.

Tools Required:

1. Hammer

2. Pair of wire cutters

3. ½-inch ratchet; 13/16-inch, 15/16-inch, ¾-inch sockets

4. Razor blade knife

5. Floor jack

6. Fork lift

7. 3/16” x 10” long T-handled Allen wrench

Uncrating Procedure

1. If machine is fully crated, remove all the 1” x 6” boards from the perimeter and top of the

crate and the 2” x 4” frame.

2. Move the machine to its approximate location.

3. Carefully cut and remove all banding and tape from parts boxes, electrical panel, control

panel, buttons, knobs and switches.

4. Bolt the electrical box to its proper location on the machine frame.

5. Un-bolt and remove the cross pieces from the skids.

6. Remove the lag bolts that secure the machine to the skids from the four foot pads at the

corners of the machine.

7. Elevate one end of the machine just high enough to make a gap between the skids and the

machine. Always check for proper lifting points for top-heavy machines.

8 990FX Operational Reference Manual, Rev. 1.2, 2007

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8. Carefully move skids outward far enough so that when the machine is lowered, the frame

rests on the ground

9. Repeat steps 7 & 8 on the opposite end of the machine.

10. Remove all the painted set collars securing the various assemblies in their shipping locations

11. Remount / Insert all routers and bits provided in the part boxes

Anchoring the 990FX

Your new Kval machine arrives at your plant crated, banded, taped, with painted set collars on all

shafts, keeping all of the precision moving parts secure during shipping.

1. To protect against damaging the machine with the forklift, move the machine as close as

possible to the area where it will be stationed before removing it from the crate

2. Use caution when removing the machine from the crate. Any time the machine is lifted

to remove the skids, there is a chance that the machine could drop suddenly, which could

damage the machine or injure people near the machine.

3. Remove all painted set collars from the shafts. Almost every shaft on the machine has set

collars to secure the moveable assembly mounted to the shafts.

4. Remove any tape securing the various buttons, switches and knobs.

5. Level your Kval machine by putting metal shims underneath the corners of the base.

Leave a clear shot from the bolt holes in the foot pads to your shop floor. Then, check to

ensure the machine will not rock back and forth.

6. Once the machine is level, anchor it to the floor so that it won’t move across the floor

during operation. Kval recommends a ½-inch Red Head, Trubolt anchor in each of the

foot pads.

Trubolt Wedge Anchor

INSTALLATION INSTRUCTIONS

1. Drill a ½-inch hole, minimum of 6-inch depth. Clean

hole.

NOTE: Kval recommends drilling completely through

the slab. If in the future the machine needs to be

moved, remove the Red Head nut and pound the

bolt flush with the floor surface.

2. Assemble anchor with nut and washer so that the top

of the nut is flush with the top of the anchor. Drive

anchor through material to be fastened so that nut

and washer are flush with surface material.

3. Expand anchor by tightening nut 3 to 5 turns (torque

requirement 55 ft. lbs for a ½-inch Red Head Trubolt).

990FX Operational Reference Manual, Rev. 1.2, 2007 9

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Overview of the 990FX

KVAL’s 990FX is the fastest, most efficient pre-hanging system available in the industry. This

machine is generally used in conjunction with a special version of the Handler door feeder, a 700-

C assembly table, and the 960-3 strike jamb router. Utilizing this assembly line, three complete

doors can be pre-hung in one minute.

The 990FX is designed to rout a door and jamb for three hinges; drill pilot holes for the hinge

screws; mortise for the lock; and apply three hinges to both door and jamb. The 990FX also

performs faceplate routing and boring for lock and bolt. The machine includes automatic door-

width adjustment to accommodate mixed stacks, and automatic door positioning with a two-speed

feed belt system. Complete cycle time, including hinge application, is a 20-second period.

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 applicators.

Pressing the “Hinges Loaded” button fastens all three hinges simultaneously.

Safety First!

The 990FX 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 damage to

equipment and/or serious injury to personnel.

Safety Guidelines

In addition to the caution and warning labels affixed to the 990FX system, follow the guidelines

below to help ensure the safety of equipment and personnel.

Guideline Description

Safety Training You must ensure that all operators of this machine be trained to know the

potential electrical hazards, pressure pinch points, rotating cutters, and other

similar hazards. 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.

Protective Gear Never operate the machine without proper eye and ear protection.

Entering the

Safety Cage When changing tools:

o When the safety cage doors are opened, all electrical power is killed.

o Wait until all motors have completely stopped moving before

entering the cage to change the bits.

Compressed Air The compressed air system connected to this machine should have a three-

way air valve for shut-off and pressure relief. The air supply providing the

pressure to this machine also has a three-way air valve for the supply line.

All cylinders on machine are under high pressure and can be very

dangerous when activated. Before performing any maintenance or

repairs on machine, turn the main air disconnect off. Lock-out and

tag-out this connection.

10 990FX Operational Reference Manual, Rev. 1.2, 2007

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Guideline Description

Electrical Electrical circuitry on this machine is protected by an approved lockable

disconnect circuit. In addition to this equipment, you must install an approved

disconnect for the electrical power supplying this machine.

This machine may be supplied by more than one power supply depending on

the options for this machine. Power is supplied at two different locations.

Before performing any repairs or maintenance, lock out and tag out both

locations. 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. All maintenance and repairs to electrical circuitry

should only be performed by a qualified electrician.

Before

Conducting

Maintenance

Prior to performing any maintenance, repairs, cleaning or when clearing

jammed debris, you must disconnect, lock out and tag out the electrical and

air pressure systems. This should be done in accordance with the state

and/or federal code requirements.

Compliance with

Codes and

Regulations

KVAL Inc. 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 regulations which apply in your geographic area.

Other Hazard

Control Actions If you believe any part or operation of this machine is in violation of any health

or safety regulation, it is your responsibility to immediately protect your

employees against any such hazard and bring the matter to our attention for

review and correction, if deemed advisable.

Additional detailed safety guidelines are included in the operating instructions

of this manual (lock-out/tag-out procedures and zero-energy start-up

instructions). KVAL will be pleased to review with you any questions you may

have regarding the safe operation of this machine.

Lock-Out/Tag-Out Procedure

This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991.

Use the following lock-out procedure to secure the 990FX while it is powered down. During a

lock-out, you disconnect all power and shut off the air supply. Be sure to use the tag-out

guidelines noted below (page 1-5).

To lock out the 990FX

1. Assess 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. Disconnect power (main electrical panel.)

NOTE: Always lock out electrical disconnects on both the large and small electrical

cabinets:

a. Turn the disconnect switch on the main electrical panel to the OFF position. Then

Still has power

in OFF position

110 VAC

power

990FX Operational Reference Manual, Rev. 1.2, 2007 11

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pull out the red tab and place a padlock through the hole. Place your tag on the

padlock, as per the tag-out guidelines below. (see example below)

5. Turn the main air valve to the OFF position and place a

padlock through the hole (see illustration).

NOTE: Place your tag on the padlock, as per the tag-

out guidelines below.

6. Once the locks and tags are in place, try to operate the

machine to ensure all energy sources are defeated.

7. When maintenance or repairs are completed, the person

who performed 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 must inspect the

equipment to ensure that the machine will not be put in an unsafe condition when re-

energized.

9. The locks and tags can then 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.

When multiple people

are working on the

machine, each person

needs to have a lock

on the handle in the

extra holes provided.

12 990FX Operational Reference Manual, Rev. 1.2, 2007

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ical ta

Lock and Tag-Out Guidelines

 Place a tag on all padlocks. On the tags, include

your name and date.

 These locks are only to be removed by the

person whose name is on the tag.

 If more than one person is working on the

machine, then each additional person places a

lock and tag on each disconnect.

 You may only remove your own lock and tag.

NOTE: When many people are all working on the same machine you will need a multiple lockout

device, such as the one shown here.

990FX Operational Reference Manual, Rev. 1.2, 2007 13

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Chapter 2: Setting up the 990FX

Front Section

Setting Up Hinge Centers

Preliminary Hinge Center Set-Up

During preliminary hinge center set-up, the H-blocks must be positioned, door stops must be set

for the left and right hand doors, and jamb stops must be adjusted. During this set-up procedure,

check positioning of each of the assemblies before adjusting. In most cases, they will already be

positioned to your specifications by our technicians during manufacturing.

Positioning H-Blocks

The first station is precision-located, and is the reference point for all set-up procedures. A door

does not need to be in the machine for initial setup. The goal of the set-up is to distance between

H-blocks to agree with you hinge center specifications.

1. Measure center-line to center-line from the center routing station H-block to one of the H-

blocks on the outboard routing stations.

2. If spacing is incorrect adjust the hinge center on the opposite end of the machine, measuring

from the center H-block. If adjustment is needed, loosen the two H-block mounting bolts and

nudge the block until the distance is the same as your specifications.

3. Re-tighten routing station mounting bolts… re-check measurement, adjust if necessary.

4. Repeat step 1-3 until hinge centers are to you specifications.

Centering Routers Within the H-Block

Once the H-blocks have been positioned to coincide with your hinge center dimensions you have

to center the router within the H-block. With routers properly centered you can move the entire H-

block without having to re-adjust router positioning.

1. Shift router as far left as possible.

2. When centering the router, reference off the tip of the router bit cutter blade which has been

rotated to extend as close as possible to the inboard edge of the H-block.

3. Adjust router position so that the blade tips are 1 inch from the (left) inside edge of the H-

block.

4. Shift router as far right as possible.

5. Adjust the router position so that the blade tip is 1 inch from the (right) inside edge of the H-

block.

6. Repeat for all routing stations.

14 990FX Operational Reference Manual, Rev. 1.2, 2007

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Setting Up the Hinge Backset

The hinge backset on the 990FX is controlled by two positive stop bolts on each of the three

routing carriages.

• To adjust loosen the lock nut and adjust the bolt accordingly to give the right hinge backset.

• Re-tighten the lock nut so that the bolt does not move out of place.

Setting the Doorstops

The 990FX comes equipped with two door stops; one for right hand doors and one for left hand

doors. The doors stops accurately position the door so that the hinge locations are consistent.

With hinge centers set and the routers centered within the H-block, you are now ready to set your

door stops. Remember 990FX always reference off of the top of the door. Right-hand doors

reference off of the left infeed door stop. Left-hand doors reference off of the right out feed door

stop.

1. To set you door stop use your specification from the top of the top hinge pocket to the top of

the door (7 inches in a 7-11 set-up).

2. Machine door. Measure from the top of the door to the top of the hinge pocket. If the pocket

is less than 7 inches, move the stop away from the hinge router. If the pocket is more than 7

inches, move the stop towards the hinge router.

3. Loosen the door stop fastening bolts. Slide foreword or backward until the inboard edge of

the door stop is positioned 1 inch less than your specified dimension from step 1.

4. Tighten door stop fastening bolts.

5. Load a door, clamp it, and rout the hinge pockets into the door only.

6. Measure your hinge centers, and the distance from the top of the pocket to the top of the door.

If hinge pocket locations are correct you can set-up your jamb stops. If hinge centers are off,

or the distance from the top of the pocket to the top of the door is incorrect, re-adjust the door

stops or “H” block locations before setting up your jamb stops.

Back Section

Before setting up the back section you should test the various assemblies without bits or cutters

installed to ensure that everything is functioning properly.

1. Remove the two drilling bits from both the lock bore and the side drills, and back out the plate

router so that it won’t drag on the door edge and turn it off using the router switch

2. At the control panel turn on the lock bore and side drills and faceplate router, and turn the

back/front/both selector to back.

3. Turn on the control transformer and press the start machine button, push the start sequence

button at the operators panel

4. Lock bore and router should come up at the same time, and move through their respective

motions

5. Lock bore lowers and router shifts out.

6. Bolt drill will then move inward.

990FX Operational Reference Manual, Rev. 1.2, 2007 15

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Check to ensure the cycle performs as previously stated. Look for sticking or uneven movement

of each assembly. Look for physical obstructions interfering with proper movement of the

assemblies.

Once the back section is running smoothly, stop operation and replace the two drill bits into the

respective collets; turn on and push in the plate router using the Acuflex wrench. Use a cull door

you can ruin and make a practice cut following the next few steps.

After the bits have been installed, install a new chip-out by removing the two 1-inch collars in

front of the chip-out housing. Then you can slide the whole assembly off to expose the old chip-

out for easy replacement. There are four ¼-inch flat head bolts that hold the two plates that hold

the chip-out in place. By loosening all four bolts on the plate you can remove the old chip-out and

replace it with a new one. Make sure that the chip-out is even when placed in position, and that all

four bolts are tightly fastened. It should be hanging lower than the surrounding metal plates. It is

critical that the chip-out is tight and flush with the tow brackets; otherwise the chip-out can vibrate

loose.

1. Load the door into the machine.

2. Clamp the door in place using the “Door Clamp” foot pedal.

* Be careful to avoid the pinch points such as between the hinge router faces, H-blocks, door

edges, etc…

3. Press the “Burn Chipout” button on the manual run touchscreen. The “burn chip-out”

mechanism is only active when this button is held down, similar to the trigger of a power

drill: when it is released, the action halts. This allows the operator to burn the chip-out in

controllable increments. Activate the chip-out bore by tapping the button, listening until you

hear the bore emerge on the other side of the chip-out block.

NOTE: Pressing the “Door Clamp” foot pedal should bring in the back section and pivot down

the jamb clamps.

Setting Up Lock Height

Now that the hinges are in there right places, and your door stops have been set, you can adjust the

lock section to put the lock in the right place, relative to the door stop.

NOTE: Check door to make sure it is square. It is important that you set the lock height with a

good door. Check the door for square by measuring the door diagonally point to point,

and again from opposite points (measure an “X” across the door). If both

measurements are the same, the door is square and good to go for set-up.

First clamp door against the stop that the machine is set-up for. Normally the back section shifts

away from the door stop that is being used. Also, depending what your hinge locations are from

the top of the door, down to the back section location will vary from one machine to the next.

The standard set-up would be 2 inches of stop pin in both stop locations to equal 44 from the top

to the center line of the lock bore.

NOTE: Before changing the lock bore location, turn power OFF, as well as the air supply at

the slide valve located next to the back section valve bank where the air supply enters

the back section. To change the lock bore location, you can add or subtract pins to

achieve the desired position to remove stop pins; for small adjustments, you can

simply change the bolt.

Setting Up Lock Bore Backset

The lock bore backset (the distance from the center line of the lock bore to the door’s edge) is

controlled by four adjustable turret stops. KVAL’s factory setting for the lock bore turrets

accommodates 5”, 2.75” and 2.375”.

16 990FX Operational Reference Manual, Rev. 1.2, 2007

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

If No Auto Backset on 990FX: Side Drill (Latch Hole)

The side drill bit has a 4-inch long fluted section. A 6-inch bit is necessary for backsets and over-

bored deadbolts. Be certain the machine is locked out electrically and the air service is

disconnected. Finally, wait until the bit has come to full stop before getting out the collet

wrenches.

NOTE: Be certain that the face plate router depth is correct and that the router chord is

fastened to the router as shown; otherwise, the long bit will eat the router.

Lock Bore Diameter

Lock out air and electrical service. Use collet wrenches to put in the appropriate face boring bit.

Replace chip out block with a new one, or a block previously used for the hole diameter.

Plate Width: Plate Router Vertical Travel

Plate router vertical travel is established by rotating stop turrets like those found on the hinge

section. These turrets have four positions: set-ups for 1” and 1/8” for either square edge or three-

degree beveled edge. These bolts are color-coded:

• Red=1” square edge

• Blue=1-1/8” square edge

• Silver=1” beveled edge

• White=1-1/8” beveled edge

Notice that no change need be made to these turrets to change among doors of varying thickness

since the lock section centers the door when it clamps. If for some reason the faceplate is not

centered on the latch hole, you can adjust the screws that contact the turret bolts. If both the plate

and latch hole are off-center, contact KVAL for instructions on shimming the self-centering clamp

system. The turret bolts should never be adjusted, since these were micrometer-set at the factory.

Plate Router Depth

The router turret sets the plate cut depth. The machine is usually set to 0-degree upon shipment.

When planning to machine a three-degree beveled faceplate, the router must be moved inward by

adjusting the router turret.

Adjust Plate Router for Three-Degree Bevel Set

Follow the steps below to adjust the router from a zero-degree bevel to a three-degree bevel.

1. Loosen the bolts holding the router in place to allow

the router motor to be moved away from the

machine. Pull the router away from the machine.

2. Turn the turret to align the silver or white bolt

(depending on the beveled edge measurement- see

above key) with the router depth adjustment bolt.

3. Slide the router back into position and tighten the

bolts to secure.

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Kval 990-FX Owner's manual

Brand: Kval

Model: 990-FX

Type: Owner's manual

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Kval 990-FX Owner's manual

Kval 990-FX Owner's manual

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