Kval 990-H User manual

Innovation, Quality & Honesty

Service Manual

: May 14, 2020

990-H Pre-Hanging Door System

Service Manual 990-H

KVAL 990-H Service Manual

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KVAL 990-H Service Manual

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KVAL 990-H Service Manual

Table of Contents

KVAL 990-H Service Manual

Chapter 1 Introduction to the 990-H

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

Overview of the 990-H Door Hanging System......................... 1-2

Operation..............................................................................................1-2

Features................................................................................................1-2

Options and Specials Available ............................................................1-3

About this Manual.................................................................................1-5

Safety First!.............................................................................. 1-6

Safety Sheet Sign-Off Sheet.................................................................1-6

Safety Terminology of Labels................................................................1-6

Safety Guidelines..................................................................................1-6

Lockout-Tagout Guidelines...................................................... 1-10

Follow the P-R-O-P-E-R lockout rule of thumb...................................1-10

Lockout Tagout Procedure....................................................... 1-11

Pre-Steps Before Lockout Tagout.......................................................1-11

Lockout Tagout Power........................................................................1-11

Lockout Tagout Air Supply..................................................................1-12

Start Maintenance...............................................................................1-12

Post Maintenance Steps.....................................................................1-12

Zero-Energy to Start-Up........................................................... 1-13

Getting Help from KVAL........................................................... 1-15

On-Line Help.......................................................................................1-16

Product Return Procedure..................................................................1-16

How to Download the Service Application............................... 1-17

Download Application.........................................................................1-17

Safety Sign-Off Sheet.............................................................. 1-20

A Note to the Operator........................................................................1-20

Chapter 2 System IT Administration

System IT Administration......................................................... 2-2

About the 990-H Computer...................................................................2-2

Connections on the PLC.......................................................................2-2

Backing up the Computer.....................................................................2-3

About Remote Connection to KVAL Service.........................................2-3

Network System Overview....................................................... 2-4

Connections to Servo Drives................................................................2-5

High Frequency Panel Node Connections............................................2-6

Frame Node Connections.....................................................................2-7

990-H

Table of Contents

Back Section Node...............................................................................2-7

Screw Driver Nodes 1-3........................................................................2-8

Chapter 3 Maintenance of the 990-H

Maintenance Schedule............................................................ 3-2

300 Cycle Maintenance Steps................................................. 3-4

Clean, Clean, Clean!.............................................................................3-4

600 Cycle Maintenance Steps................................................. 3-5

Check Air Gauges and Inspect Water Traps ........................................3-5

Inspect Tooling......................................................................................3-5

Lubricate inside of Hopper....................................................................3-6

Empty Dust Collection Units.................................................................3-6

3,000 Cycle Maintenance Steps.............................................. 3-7

Inspect Feed Belts................................................................................3-7

Inspect Screw Drop Tubes on Six Shooter...........................................3-7

Inspect all Photo Eyes..........................................................................3-7

Inspect Limit Switches..........................................................................3-8

Inspect Screw Receiver Parts...............................................................3-8

Inspect Airlines .....................................................................................3-9

Refill Lubricators...................................................................................3-9

Grease Ball Screw Bearings...............................................................3-10

Clean Bearing Shafts..........................................................................3-10

12,000 Cycle Maintenance Steps............................................ 3-11

Inspect Chains for Proper Tension......................................................3-11

Inspect Air Cylinders...........................................................................3-11

Inspect Hydraulic Lines.......................................................................3-11

Inspect Ball Rail Shafts and Ball Screw..............................................3-12

Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........3-12

Clean inside Hopper...........................................................................3-12

72,000 Cycle Maintenance Steps............................................ 3-13

Inspect Nuts and Bolts........................................................................3-13

Check Door Feeding Transition..........................................................3-13

Electrical.............................................................................................3-13

Computer Backup...............................................................................3-13

Wash Filter and Lubricator Bowls.......................................................3-13

Tool Changing Schedule.......................................................... 3-14

Maintenance NO-GOES.......................................................... 3-16

Lubrication Schedule............................................................... 3-17

Typical Lucubration Kit........................................................................3-17

Table of Contents

KVAL 990-H Service Manual

Lubrication Requirements........................................................ 3-18

Pillow Block Bearing Housings...........................................................3-18

Flange Bearing Housings ...................................................................3-19

Ball Rail Bearing.................................................................................3-19

About Taper Bearings.........................................................................3-20

Tapered Bearing Housings .................................................................3-20

Ball Screw Nut....................................................................................3-21

Ball Screw Drive Assembly.................................................................3-21

Pulley and Idler Shafts........................................................................3-22

Lubrication Points on the 990-H .............................................. 3-23

Feed System Lube Points...................................................................3-23

Screw Driver Lube Points...................................................................3-24

Back Section Lube Points...................................................................3-25

Head Lube Points...............................................................................3-26

Servo Motor Location............................................................... 3-27

Back Section Servo Motor Assembly..................................................3-27

Front Section Servo Assemblies.........................................................3-28

Description of Air Input System ............................................... 3-29

Air Input with Lubrication ...................................................................3-29

Air Line Without Lubricator .................................................................3-30

Replacing Tooling in the Front Section.................................... 3-31

Standard Carriage Tools.....................................................................3-31

Carriage Tools with Counter Rotate Router........................................3-32

How to Access to Bit Assemblies .......................................................3-32

Remove and Replace the Router or Pre-Drill Bits..............................3-33

Remove and Replace the Chisels ......................................................3-35

Remove and Replace the Screwdriver Bits........................................3-35

Replacing Tooling in the Back Section..................................... 3-37

Changing the Bore Drill.......................................................................3-37

Changing the Bolt Drill........................................................................3-38

Collet Torque Values................................................................ 3-39

Appendix: Conversion Chart.................................................... 3-41

Chapter 4 Trouble Shooting of the 990-H

About Motion Control............................................................... 4-2

Basic Control Circuit.............................................................................4-2

Troubleshooting Basics ........................................................... 4-4

Before you Adjust .................................................................................4-4

Before you Adjust .................................................................................4-5

990-H

Table of Contents

Analyze the Sub Systems.....................................................................4-5

About a Typical Contactor Control........................................... 4-7

About Contactor Troubleshooting.........................................................4-8

About Typical VFD Motor Drive Control................................... 4-9

About the VFD....................................................................................4-10

About VFD Troubleshooting ...............................................................4-11

About a Typical Pneumatic Circuit........................................... 4-12

Typical Pneumatic Assembly..............................................................4-13

About the Coil (Solenoid)....................................................................4-13

About Cylinder Operation ...................................................................4-14

How the Pneumatic System Works ....................................................4-14

Important Notice about Adjusting Cylinder Speed..............................4-16

Adjusting Cylinder Extend Speed .......................................................4-17

Adjusting Cylinder Retraction Speed.................................................4-17

Using Sensors to Trouble Shoot.............................................. 4-18

Location of Sensors on 990-H............................................................4-18

About Switches and Sensors................................................... 4-19

Troubleshooting Electrical Problems ...................................... 4-21

If the Power Stops During Normal Operation......................................4-21

Troubleshooting with the Status Light Panel ........................... 4-23

Notes:

Chapter 1 at a Glance

1-1

KVAL 990-H Service Manual

CHAPTER 1 Introduction to the 990-H

This chapter provides an overview of the KVAL 990-H Door Hanging System and important

safety information to follow when operating the machine.

Chapter 1 at a Glance

Section Name Summary Page

Overview of the System This section provides an overview of the 990-H. It

includes a general description and a table of available

options

page 1-2

Safety First! IMPORTANT safety information is described in this

section page 1-6

Lockout Tagout IMPORTANT: Procedure to Lockout Tagout equipment

when it is being serviced. page 1-11

Zero-Energy to Start-Up Procedure to power up your machine for the first time. page 1-13

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 1-15

How to Download the

Service Application

Procedure to download an interactive application to

allow Service Technicians to control your machine and

help troubleshoot.

page 1-17

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

machine. page 1-20

Overview of the 990-H Door Hanging System

KVAL 990-H Service Manual

1-2

Overview of the 990-H Door Hanging System

The Kval Model 990-H will rout a door and jamb

for two or three hinges, drill pilot holes for the

hinge screws, rout and bore for the lock and apply

hinges.

Functions include hinge and faceplate routing and

boring for lock and bolt. Standard features include

automatic hinge routing, pre-drill, and hinge appli-

cation for two or three hinge butts on both door

and jamb. Machine also includes automatic door

width adjustment to accommodate mixed stacks

and automatic door positioning with a two-speed

feed belt system.

Operation

Door is automatically positioned while the operator loads and clamps a single hinge stile (single

hinge jamb), or jamb set complete with strike jamb and head jamb. Routing and boring occur

while the operator places hinges into the nests of the applicators. Pressing the “IN” button fastens

all hinges simultaneously.

Features

Routs two or three hinge pockets in both door and jamb, spaced so half hinges can be

mounted without pins.

Pre-drills two or three hinge pockets in both door and jamb.

Applies two or three hinges to door and jamb with the hinge separated.

Number 1, 2 & 3 hinge router assemblies are movable on THK® linear ball rail to accommo-

date 2040mm (80.31), 2240mm (88.188) & 2340mm (92.126)doors. The assemblies will be

cylinder operated and will index with 4 position stop turrets that will be manually revolved to

accommodate both door and hinge length

Hinge Routers are 1hp 3ph Hi-Frequency motors (230/380v)

Both hinge jamb stop assemblies are movable on THK® rail to accommodate 2040mm

(80.31), 2240 (88.188) & 2340mm (92.126) jambs. (Cylinder operated)

Overview of the 990-H Door Hanging System

1-3

KVAL 990-H Service Manual

Options and Specials Available

Machine will accommodate nominal door thickness of 35mm (1.377) and 40mm (1.588) with

some variation expected.

Machine will be equipped with one in-feed and two out-feed door stops that will register off of

the top of the door. The center and right hand hinge routers and screw driver heads will be

cylinder operated and will move into position to machine and apply hinges to the 2040mm,

2240 and the 2340mm door lengths

Auto positioning.

Auto width adjust.

Two independent face bore drill units to eliminate chip out. (1 top and 1 bottom 5hp drill

motors) adjustable manually from 60-70mm from the door edge

Face bore; side drill and bolt plate router will be capable of shifting up to 300mm (11.811) off

of center line of length of door in either direction. Total movement of 600mm. (23.622)

Face bore drills will accommodate a three stage drill bit both top and bottom for drilling differ-

ent diameter holes. (Tooling to be provided by customer)50mm (1.968), 35mm(1.39) &

22mm (.866). Tooling shank will be ½"diameter).

Bolt plate router will be a 1hp 3ph Hi-Frequency motor. (230/380v)*

Bolt drill will be 3hp 3phase.

Air Blow-Off on out-feed end.

Feed direction will be left to right looking from operator's side.

Machine will be capable of routing hinge pockets in the door and jamb with doors as narrow

as 520mm. Doors as narrow as 420mm can be processed with extra handling using a

spacer or packer

Option Title Description

Opt ND Narrow Doors Narrow door system adds mechanism and pro-

gramming to automatically accommodate doors as

narrow as 410mm in width, but without lock pro-

cessing (Option includes complete secondary feed

fence attached to the lock section of the 990-H that

will nest under doors when not in use)

Opt P Single Point Hinge Pre-Drill Option includes three single spindle motors (one

for each hinge) with programmed motion to pre-drill

holes in succession for hinge screws. The screw

pattern is saved and recalled by name. The cycle

adds approximately 5 seconds to that of the multi-

ple spindle pre-drill. (Requires Corner Squaring

option.)

Overview of the 990-H Door Hanging System

KVAL 990-H Service Manual

1-4

Out-Feed Pause Switch Adds an out-feed pause switch to the button panel

attached to the center screw-driving head to tem-

porarily over-ride automatic door out-feed. Allows

screws to be added or replaced with a hand held

screwdriver.

Programmable Hinge Loca-

tions This option upgrades the standard air cylinder shift

system for hinge positions along the door edge.

The cylinders and three position limit is replaced

with servo motors, ball screws and software to

adjust the outer hinge routers to any location within

the limits of the ball rail track.

Programmable Door Index

and Hinge Applicator Posi-

tioning

This option compliments the programmable hinge

location option by also adding four more servo

motors, ball screws and software control to adjust

door positioning stops and the left and right hinge

application heads. This will make it possible to eas-

ily create presets on the touch screen for multiple

door lengths, hinge locations and lock locations –

or completely custom locations can be entered for

one time use. Top hinge location can vary from

198mm and screwdrivers can be aligned with cus-

tom hinge locations.

Corner Square Feature Adds automatic corner squaring to the hinge rout-

ing sequence, and fastening of square hinges.

Price includes replacing x,y,z motion air cylinders

on each of the hinge router head with ball screws

and AC servo motor (9 total), as well as corner

square chisel assemblies. The servo motor

sequencing will add approximately 3-4 seconds to

all hinge sequences including standard radius

hinges. Adding corner squaring will add approxi-

mately 6 seconds more. 10 seconds extra overall

is estimated for a square hinge door unit (door and

jamb). Automatic adjustment between 100mm and

89mm hinges is included with a touch screen

selection, although hinge location centerlines

remain the same.

Custom lock locations in

Millimeters Ability to enter custom lock location in millimeters

using the touch screen for special doors. This will

reference the in-feed door stop

Option Title Description

Overview of the 990-H Door Hanging System

1-5

KVAL 990-H Service Manual

About this Manual

This manual is part of a package delivered with the machine line.

Integration Package includes the following:

Operation Manual includes the following:

Service Manual includes the following

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

2Operation Inter-

face Descriptions of how to power

machine line, and operator inter-

face user screens.

3Calibration Descriptions of Calibration Rou-

tines and how to use the interfaces

5Tour of DL-NCD Identification and descriptions of

the DL-NCD machine assemblies.

Chapter Title Description

1Introduction Safety Information.

2System IT Admin-

istration Descriptions of the PLC system,

and computer system.

3Maintenance Maintenance steps for the

machine line

4Troubleshooting Troubleshooting tips and theory of

operation.

Safety First!

KVAL 990-H Service Manual

1-6

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 1-20.

Safety Terminology of Labels

In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-

vide safety information to operators. Safety labels should be clearly visible to the operator and

must be replaced if missing, damaged, or illegible.

There are three types of warning labels or decals:

• DANGER means if the danger is not avoided, it will cause death or serious injury.

• WARNING means if the warning is not heeded, it can cause death or serious

injury.

• CAUTION means if the precaution is not taken, it may cause minor or moderate

injury.

Safety Guidelines

In addition to the caution and warning labels affixed to 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 1-11.

Compressed Air

Safety First!

1-7

KVAL 990-H Service Manual

Electrical circuitry on this

machine is protected by an

approved lockable disconnect

circuit. In addition to this equip-

ment, you must install an

approved disconnect for the

electrical power supplying this

machine.

When opening the cabinet you must first turn off the

disconnect switch. When the cabinet door is open there

is still power on the top side of the disconnect switch.

Some machines are powered by more than one supply

located at different locations. Before performing any repairs or mainte-

nance, lockout and tagout must be installed at all locations

All maintenance and repairs to electrical circuitry should only be per-

formed by a qualified electrician.

Still has power

in OFF position

Electrical

Prior to performing any maintenance, repairs,

cleaning or when clearing jammed debris, you

must disconnect, tag out, or lock out the electrical

and air pressure systems. This should be done in

accordance with applicable state and/or federal

code requirements.

Before Conducting Maintenance

Laser Warnings

On some machines, laser indicators are used to set boundaries. Follow the

manufacturers safety precautions.

Safety First!

KVAL 990-H Service Manual

1-8

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!

1-9

KVAL 990-H Service Manual

Lockout-Tagout Guidelines

KVAL 990-H Service Manual

1-10

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

1-11

KVAL 990-H Service Manual

Lockout Tagout Procedure

This policy is required by OSHA regulation 1910.147 and Cal OSHA’S

SB198 ruling of July 1991.

Use the following lockout procedure to secure 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

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Kval 990-H User manual

Kval 990-H User manual

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