Kval 990-H Reference guide

Innovation, Quality & Honesty 990-H System

Reference

Published: 5/18/07

990-H

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 cus-

tomers 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 2006 and 990-H are trademarks of Kval, Incorporated.

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

tions for improvement to us[email protected]. (NOTE: This is not a way to get customer sup-

port. For that, please refer to the Customer Service contact information above.) Thank you!

990-H

979-2

Table of Contents

CHAPTER 1 ....................................................................................Introduction 1

Safety First! ..........................................................................................................3

Safety Guidelines ........................................................................................3

Lock Out Procedure .......................................................................................4

To lock out the 990-H .................................................................................4

Lockout and Tagout Guidelines .....................................................................5

Follow the P-R-O-P-E-R lockout rule of thumb. ..........................................5

Zero-Energy Start-Up ..........................................................................................6

Zero-Energy State to Start-Up to Operating State .........................................6

Start-up ........................................................................................................6

Inspect .........................................................................................................6

Clean Up .....................................................................................................6

Replace Guards ...........................................................................................6

Check Controls ...........................................................................................6

Remove Locks ............................................................................................6

Perform Visual Checks ...............................................................................6

Initial Set up .........................................................................................................9

Trubolt Wedge Anchor .............................................................................10

INSTALLATION INSTRUCTIONS .......................................................10

Electrical Connections Overview ................................................................11

CHAPTER 2 ..................................................................................... Operation 13

Machine Tour .....................................................................................................15

Quick Start .........................................................................................................17

Turning the 990-H On and Off ..........................................................................19

Powering Up the 990-H ...............................................................................19

Powering up the system includes: .............................................................19

To Power Up the 990-H ............................................................................19

The machine is now ready for the homing ...............................................19

The 990-H Homing: ..................................................................................19

Powering Down the 990 ..............................................................................19

To Power Down the 990-H .......................................................................20

Emergency Shutdown and Recovery ...........................................................20

To Resume Normal Operation after an E-Stop ............................................20

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

Mechanical set up of the 990-H .........................................................................21

Front Section ................................................................................................21

Setting Up Hinge Centers ............................................................................21

Preliminary Hinge Center Set-Up .............................................................21

Positioning H-Blocks ................................................................................21

979-2

Centering Routers Within the H-Block ....................................................21

Setting Up the Hinge Backset ...................................................................21

Setting the Doorstops ................................................................................22

Back Section ................................................................................................22

Setting Up Lock Height ............................................................................23

Setting Up Lock Bore Backset ..................................................................23

If No Auto Backset on 990FX: Side Drill (Latch Hole) ...........................23

Lock Bore Diameter ..................................................................................23

Plate Width: Plate Router Vertical Travel ................................................24

Plate Router Depth ....................................................................................24

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

...................................................................................................................25

Touch Screen Interface ......................................................................................27

Main Screen .............................................................................................28

Back Section Display ................................................................................29

Presets .......................................................................................................30

About preset and working memory ..........................................................31

Preset modification overview ...................................................................32

Modify Preset ............................................................................................33

Modifying Preset Parameters .......................................................................34

Lock Location ...........................................................................................34

Lock Bore .................................................................................................35

Lock Backset .............................................................................................35

Face Plate ..................................................................................................35

Side Drill ...................................................................................................35

Manual Operation ..................................................................................36

Width Adjust and Clamp ..........................................................................37

Routers and Pretrials .................................................................................38

Feed ...........................................................................................................39

Screwdrivers .............................................................................................40

Hinge Centers ...........................................................................................41

CHAPTER 3 .................................................................................Maintenance 43

Maintenance Schedule .......................................................................................44

Daily .............................................................................................................44

Weekly .........................................................................................................44

May and December Checkups .....................................................................45

Lubrication Requirements ..................................................................................46

Linear Bearings .........................................................................................46

Flange Bearing and Pillow Blocks ............................................................46

Approved Lubrication Products for Lubricators .......................................46

Gear Motor Lubrication Requirements .....................................................46

Ball Screws ...............................................................................................46

Adjusting the Air Line Lubricator (not available on all machines) ..........47

979-2

Replacing Screwdriver Bits .........................................................................48

Grease Points ...............................................................................................49

Feed System ..............................................................................................49

Screwdrivers .............................................................................................50

Routers and Predrills .................................................................................51

Backsection ...............................................................................................52

Back Section Servo Position Calibration ...........................................................55

CHAPTER 4 ............................................................................Troubleshooting 57

Troubleshooting the Air Cylinders ....................................................................58

Adjusting Cylinder Extension Speed: ..........................................................59

Adjusting Cylinder Retraction Speed: ........................................................59

Troubleshooting Electrical Problems .................................................................60

If the Power Stops During Normal Operation ............................................60

Troubleshooting with the Status Light Panel ...............................................61

Adjusting Limit Switches ........................................................................64

Troubleshooting Photo Detectors .......................................................................65

General Operational Troubleshooting ................................................................66

Hinge Dropped During Application .........................................................66

Hinge Dropped Behind Router Head During Application ........................66

Limit - Switch Timing .......................................................................................67

General process description: .....................................................................67

990-H Limit switch timing procedure ...............................................................68

990-H Set maximum cut procedure ...................................................................69

Getting Help from Kval .....................................................................................70

Product Return Procedure ............................................................................70

Touch Screen Troubleshooting ..........................................................................71

Maintenance Screen .....................................................................................71

Machine Data .........................................................................................72

Servo Trouble Shooting ............................................................................72

PLC Communication ................................................................................73

Error Codes ...............................................................................................73

OPEN NET Main PLC ..........................................................................74

Microsmart Remote-1 ............................................................................76

Microsmart Remote-2 ............................................................................78

Microsmart Remote-3 ............................................................................81

Microsmart Remote-4 ............................................................................84

Servo Position Calibration .....................................................................86

Servo Trouble Shooting: Limit Switch Timing .....................................87

Machine Layout ........................................................................................88

Hopper Layout ..........................................................................................89

Internal Bit (M-Bit) List ...........................................................................89

979-2

Tech Support .............................................................................................90

Maintenance Back Section & Feed ........................................................90

Part Locations ....................................................................................................95

Width Adjust and Feed System ....................................................................95

Front Clamp .................................................................................................96

Front Clamp and Head positioning ..............................................................97

Back Section ................................................................................................98

Front View ................................................................................................98

Rear View .................................................................................................99

Infeed View .............................................................................................100

Outfeed View ..........................................................................................101

Valve Bank .............................................................................................102

Front Section: .............................................................................................103

Through Beams .......................................................................................103

Left Head Screwdrivers ..........................................................................104

Left Head Router and Predrills ...............................................................105

Center Head Screwdrivers ......................................................................106

Center Head Router and Predrills ...........................................................107

Right Head Screwdrivers ........................................................................108

Right Head Router and Predrills .............................................................109

RT-2 Hopper Table .....................................................................................110

Hoppers ...................................................................................................110

Table .......................................................................................................111

Warranty ...........................................................................................................113

990-H 1

CHAPTER 1 Introduction

KVAL's 990-H is the fastest and most productive pre-hanging system available in the industry.

The 990-H will rout a door and jamb for three hinges, drill pilot holes for the hinge screws, mortise for

the lock, and apply three hinges all in an incredibly-fast 20 seconds! This machine is generally used in

conjunction with the ON-3, 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.

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 auto-

matic door positioning with a two-speed feed belt system.

Operation: Door is automatically positioned while the operator loads and clamps the hinge jamb. Rout-

ing and boring occur while the operator places hinges into the nests of the three hinge applicators.

SPECIFICATIONS

Footprint Size: 12'L x 9'W

Crated Dimensions: 175"L x 94"W x 104"H

Shipping Weight: Approximately 6,000 lbs.

Introduction

2990-H

Safety First!

990-H 3

Safety First!

The 990-H 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 seri-

ous injury to personnel.

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.

Guideline Description

Safety Training 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 the machine is on:

• Never reach hands beyond safety cage. If the machine has servo motors

can unexpectedly move quickly and out of control.

• Do not clear slugs out of the machine while it is running.

• Never perform any maintenance while machine is running.

• Never clean the machine while it is running.

• Never walk away from the machine while it is running.

Compressed Air .

Electrical 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 electri-

cal power supplying this machine.

When opening the cabinet you must first turn off the discon-

nect 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, tag-out and lock-out the electrical and air pressure sys-

tems. This should be done in accordance with the state and/or federal code require-

ments.

Compliance with

Codes and Regula-

tions

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.

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

valve for shut-off and pressure relief. The air supply line providing the pressure to this

machine also has a three-way air valve. All cylinders on the machine

are under high pressure and can be very dangerous when activated.

Before performing any maintenance or repairs on the machine, turn the

main air disconnect off. Lock-out and tag-out this connection.

Still has power

in OFF position

4990-H

Lock Out 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,

disconnect all power and shut off the air supply. Be sure to use the tag-out guidelines noted below.

To lock out the 990-H

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.

NOTE:Always lock out electrical disconnects on both electrical cabinets

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 tag-

out guidelines below. (see picture below).

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

tag-out guidelines below

Other Hazard Control

Action 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. KVAL will be pleased to review with you any questions you may have regard-

ing the safe operation of this machine.

When multiple people are

working on the machine, each

person needs to have a lock on

the handle in the extra holes

provided.

Safety First!

990-H 5

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. Insure the machine will not operate.

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 shall inspect the equipment to ensure that

the machine will not be put into 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 and Tagout 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 working on the same

machine, a multiple lockout device is necessary.

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 establish, insure and achieve a zero-energy state

R ...... Re-check controls and test to ensure they are in the “OFF” position

6990-H

Zero-Energy Start-Up

Zero-Energy State to Start-Up to Operating State

Starting the equipment properly is just as important as the lock-out/tag-out procedure in terms of safety.

Start-up

• Inspect

• Clean up

• Replace guards

• Check controls

• Remove locks

• Perform visual checks

Inspect

When work is finished, the equipment must be inspected for proper adjustment before starting equip-

ment.

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, leave only that guard off.

Check Controls

Confirm that all switches are in the “OFF” position. In some cases, the machine can start automatically

when energy is restored.

Remove Locks

Each person must remove his or her own lock and tag. This will ensure operators 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 person-

nel alarm before starting the equipment. If your operation is more complex, having many pieces of

equipment and a lot of people, a comprehensive lock-out/tag-out procedure may involve additional

steps. You will need to ask your supervisor about these procedures. A specific lock-out procedure may

be posted at each machine. On larger or long-term maintenance or installation projects, the procedures

should be explained to all participants and a copy of the procedures should be posted on-site for the

duration of the work. Provisions which ensure protection during shift changes when contractor or out-

side help is used must also comply with the lock-out/tag-out procedures. Comprehensive lock-out/tag-

Zero-Energy Start-Up

990-H 7

out may use a gang box or other system to ensure that locks are secure and not removed without autho-

rization.

Remember, lock-out/tag-out procedures work because you are the only one with the key to your lock.

Proper lock-out/tag-out can save lives, limbs, and money. Help make your work environment safe for

yourself and your fellow workers. Be sure to follow the P-R-OP-E-R lock-out/tag-out procedures, and

that those around you do also.

YOUR LIFE MAY DEPEND ON IT.

8990-H

Initial Set up

990-H 9

Initial Set up

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. Level your Kval machine by put-

ting metal shims underneath the corners of the base. Leave a clear shot from the bolt holes in the foot

pads to your shop floor.

5. Once the machine is level, anchor it to the floor so that it won't move across the floor during opera-

tion. Kval recommends a ½-inch Red Head, Trubolt anchor in each of the foot pads.

10 990-H

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

Initial Set up

990-H 11

Electrical Connections Overview

The main electrical power is connected to the disconnect,

located in the large electrical panel on the back side of the

machine on the infeed end.

The 990-H requires three phase power. Refer to the plant

layout diagram or the brass information plate to determine

the voltage required.

3 Phase input GND

12 990-H

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Kval 990-H Reference guide

Kval 990-H Reference guide

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