Kval 990-FX User manual

Innovation, Quality & Honesty

Service Manual

Published: May 12, 2022

990-FX Pre-Hanging Door System

Metal Jamb and Door Machine

990-FX Service Manual

KVAL 990-FX Service Manual

Proprietary Notice

This Manual is confidential and contains proprietary information and intellectual

property of KVAL Inc., and is to be used solely by Customer as an operating manual

for KVAL Inc. machines. Neither this Manual nor any of the information contained

herein may be reproduced or disclosed under any circumstances without the express

written permission of KVAL Inc. For authorization to copy this information, please

call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the

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

Manual Name: 990-FX Service Manual

Rev: 93-MV 102.0

990-FX is a trademark of Kval Incorporated.

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

Beckhoff Automation GmbH

Windows ® is a registered trademark of Microsoft Corporation.

All other products are trademarks or registered trademarks of their respective

affiliation with or sponsorship of Kval Incorporated.

Contacting KVAL

Customer Service: For further information about this manual or other Kval Incorpo-

rated products, contact the Customer Support Department

• Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

• Phone and Fax:

In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

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

• Business hours:

Technical Support:

6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday

6:30 AM to 1:30 PM Pacific Standard Time, Friday

Parts & Service Sales:

6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday

6:30 AM to 1:30 PM Pacific Standard Time, Friday

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

• Email: [email protected]

KVAL 990-FX Service Manual

Your Feedback is Welcome: To help us design products that make your job easier

and your business more successful, we'd like to gain your perspective about your user

experience with our product - that is, the manual, the machinery, the software, etc.

What was easy or difficult to use or to learn? If you could change something about the

design, what would it be? Please email your comments and suggestions for improve-

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link. For that, please refer to the Customer Service contact information above.) Thank

you!

http://www.kvalinc.com

KVAL 990-FX Service Manual

Table of Contents

990-FX Service Manual

Chapter 1 Introduction to the 990-FX

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

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

Hopper Options.....................................................................................1-2

Table of Available Options ....................................................................1-3

About this Manual.................................................................................1-4

Safety First!.............................................................................. 1-5

Safety Sheet Sign-Off Sheet.................................................................1-5

Safety Terminology of Labels................................................................1-5

Safety Guidelines..................................................................................1-5

Lockout-Tagout Guidelines ...................................................... 1-9

Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9

Lockout Tagout Procedure....................................................... 1-10

Pre-Steps Before Lockout Tagout.......................................................1-10

Lockout Tagout Power ........................................................................1-10

Lockout Tagout Air Supply ..................................................................1-11

Start Maintenance...............................................................................1-11

Post Maintenance Steps.....................................................................1-11

Zero-Energy to Start-Up .......................................................... 1-12

Getting Help from KVAL........................................................... 1-14

Kval Return and Warranty Policy............................................. 1-16

Send the Item .....................................................................................1-16

Acceptance of Return .........................................................................1-16

Refund Turnaround Time ....................................................................1-16

Kval Errors..........................................................................................1-16

Customer Errors .................................................................................1-17

Shipper Errors.....................................................................................1-17

Warranty Replacement Parts..............................................................1-17

How to Download the Service Application ............................... 1-18

Download Application .........................................................................1-18

Safety Sign-Off Sheet .............................................................. 1-21

A Note to the Operator........................................................................1-21

Chapter 2 System IT Administration

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

Network Diagram..................................................................................2-3

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

Procedure for Backing up Data.............................................................2-3

990-FX Service Manual

Table of Contents

Chapter 3 Maintenance of the 990-FX

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 Screws............................................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 .......................................................3-14

Tool Changing Schedule.......................................................... 3-15

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

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

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

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

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

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

Table of Contents

990-FX Service Manual

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-FX ............................................ 3-23

Back Section.......................................................................................3-25

Heads .................................................................................................3-26

Servo Motor Assembly........................................................................3-27

Hubs ........................................................................................ 3-28

Description of Air Input System................................................ 3-30

Air Input with Lubrication ...................................................................3-30

Air Line Without Lubricator .................................................................3-31

Replacing Bits.......................................................................... 3-32

Replacing Bits in the Front Section ....................................................3-32

How to Access to Bit Assemblies........................................................3-33

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

Replacing Tooling in the Back Section..................................... 3-36

Option SB (CNC Back Section) ..........................................................3-37

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

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

Chipout Block Replacement .................................................... 3-39

Burn Chipout.......................................................................................3-39

To Replace the Back Section Chipout Block............................ 3-40

Tools ...................................................................................................3-40

To Replace the Front Section Chipout Block ........................... 3-41

Summary of Burn Process..................................................................3-41

Chipout Block Spacers .......................................................................3-41

Procedure to Change Front Chipout Block.........................................3-42

Tools ...................................................................................................3-42

Collet Torque Values................................................................ 3-44

Chapter 4 Troubleshooting the 990-FX

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

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

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

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

990-FX Service Manual

Table of Contents

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

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................................................................4-10

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

Troubleshooting Electrical Problems ....................................... 4-19

If the Power Stops During Normal Operation .....................................4-19

Troubleshooting with the Status Light Panel .......................... 4-21

Network System Overview....................................................... 4-25

Connections to Servo Drives ..............................................................4-25

Symptoms and Possible Causes ............................................. 4-26

Chapter 1 at a Glance

1-1

KVAL 990-FX Service Manual

CHAPTER 1 Introduction to the 990-FX

This chapter provides an overview of the KVAL 990-FX 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 990-FX

System

This section provides an overview of the 990-FX This

section includes a general description and a table of

available options

page 1-2

Safety! IMPORTANT safety information is described in this

section

page 1-4

Zero-Energy to Start-Up Procedure to power up your machine for the first time. page 1-12

Getting Help from KVAL This section describes the method to contact the KVAL

service center for help. The section includes how to get

information from the specification plate tor provide to

KVAL, service center hours, and return procedures

page 1-14

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

machine.

page 1-21

Overview of the 990-FX Door Hanging System

KVAL 990-FX Service Manual

1-2

Overview of the 990-FX Door Hanging System

Note: This 990-FX with new heavy duty features making it purpose built for companies running three

shifts per day.

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

The 990-FX will rout a door and jamb for three or four hinges, drill pilot holes for the hinge

screws, mortise for the lock, and apply three or (Opt four) hinges.

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. Machine also includes automatic door width adjustment to accommodate mixed stacks

and automatic door positioning with a two-speed feed belt system.

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

Routing and boring occur while the operator places hinges into the nests of the three hinge appli-

cators. Pressing the "In" button fastens all three hinges simultaneously. Price includes operator

training and machine checkout by a KVAL technician in the customer's plant.

Metal Door and Jamb Machine

This machine is equipped with a metal sensor that alerts the machine to process metal doors and

metal jambs.

Machine Footprint

Overview of the 990-FX Door Hanging System

1-3

KVAL 990-FX Service Manual

Table of Available Options

For detailed information about available options, please contact our KVAL Sales and Service

Department.

Option Title Description

Option C Pushbutton Selection for Face Bore

Backsets

For two face bore backsets between 2-3/8" and 2-3/4". Manual

adjustment takes 5 to 10 minutes.

Option DC Dust Take-Off Rees-Memphis Model C730-2 dust collection fan and filter with

silencer and magnetic starter. 7.5HP totally enclosed fan cooled

motor wired for 3 phase voltage. Each tube collector includes a

cartridge filter with 322 square feet of blended media in place of

standard 25 sq. ft. filter bags.

Option H Split Jamb Stapler Clamps and fires two wide-crown staples to fasten the male and

female hinge jambs members together during the routing

sequence. Requires staple gun which is not included in the price.

Please note that this option reduces the minimum width of a door

that can be machined to 18

Option I Reverse Feed Facing the hinge routers, the normal feed direction is left to right.

Option IL Door Hand Indicator Light Light will be mounted on the out-feed end of the 990-FX that

can be seen by the 700-C Assembly Table operator. The light will

be on when the door in the 990-FX is being machined as a right

hand door and off for a left hand door.

Option N Dust Blow off System Air blow-off tube cleans dust and chips from the top of a door.

Option T High-Frequency Hinge Routers Three 1 HP 230/380v high-frequency hinge routers and drive

units with 1/2" collet.

Option U High-Frequency Bolt Plate Router One 1 HP 230/380v high-frequency bolt plate router with drive

unit and 1/2" collet.

Option Z Screw Changing Hoppers Screw-changing hoppers for changing screw colors. Price

includes three 6-slot screw hoppers.

Option Tooling and Lubricant Package Please review with your KVAL consultant to determine your

needs.

Option Spare Parts Package Please review with your KVAL consultant to determine your

needs.

Overview of the 990-FX Door Hanging System

KVAL 990-FX Service Manual

1-4

About this Manual

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

Integration Package includes the following manuals:

Operation Manual

Service Manual

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

2

Operation

Interface

Descriptions of how to power

machine line, and use operator

interface user screens.

3Tour of the

Machine

Highlights of the machine assem-

blies

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

2IT System Examples of PLC of the

machine.

3Maintenance Maintenance steps for the

machine line

4Troubleshooting Troubleshooting tips and theory

of operation.

Safety First!

1-5

KVAL 990-FX Service Manual

Safety First!

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 1-21.

Safety Terminology of Labels

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

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.

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.

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

Safety First!

KVAL 990-FX Service Manual

1-6

Never operate the machine without proper eye and

ear protection.

Protective Gear

• Never reach hands beyond safety cage. Servo

motors can unexpectedly move quickly.

• Never clear screws or hinges out of the machine

while it is running.

• Never reach into the router area to retrieve a

hinge. The router may still be running down

after shut down.

• Never perform any maintenance unless machine

is at zero state.

• Never clean the machine while it is running.

• Never walk away from the machine while it is

running.

When the Machine is ON

The compressed air system connected to this

machine should have a three-way air valve

for shut-off and pressure relief.

All cylinders on machine are under high

pressure and can be very dangerous when

activated. Before performing any mainte-

nance or repairs on this machine turn off the

main air disconnect. Lockout and tagout

this connection.

See “Lockout Tagout Procedure” on

page 1-10.

Compressed Air

Safety First!

1-7

KVAL 990-FX 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-FX 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.

Lockout-Tagout Guidelines

1-9

KVAL 990-FX Service Manual

Lockout-Tagout Guidelines

• Place a tag on all padlocks. On the tag, each

operator must put their own name and date.

(These locks are only to be removed by the

person who signs the tag)

• If more than one person is working on the

machine, each additional person places a lock

and tag on each disconnect.

• Only each operator may remove their own

lock and tag.

Important: When many people are all working

on the same machine you will need a multiple

lockout device, such as the one shown here.

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

P...... Process shutdown

R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)

O...... OFF! Shut off all power sources and isolating devices

P...... Place lock and tag

E...... ENERGY: Release stored energy to a zero-energy state

R ...... Recheck controls and test to ensure they are in the “OFF” state

Lockout Tagout Procedure

KVAL 990-FX Service Manual

1-10

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

Lockout Tagout Power

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.

4. Turn off machine. See Chapter 2 for power down and power up procedures.

5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF

position. Then push the red tab to pop it out. Place a padlock through the hole.

Place your tag on the padlock, as per the tagout guidelines below. (see illustration

below).

Power

Note: When multiple people are working on the machine, each person needs to

have a lock on the handle in the extra holes provided.

Insert Lock into hole.

Turn Switch to the

OFF position

Lock and Tag out

Lockout Tagout Procedure

1-11

KVAL 990-FX Service Manual

Lockout Tagout Air Supply

Start Maintenance

7. Once the locks and tags are in place and all personnel are clear, attempt to operate

the machine to ensure equipment will not operate.

8. Maintenance or repairs may started.

Post Maintenance Steps

9. After maintenance is completed, the person performing the work must ensure all

tools, spare parts, test equipment, etc., are completely removed and that all guards

and safety devices are installed.

10. Before removing the locks and tags, the person who attached them shall inspect the

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

re-energized.

11. The lock and tag can now be removed (only by the person(s) who placed them),

and the machine can be re-energized.

12. The tags must be destroyed and the locks and keys returned to the lockout center.

6. Turn all air valves to the OFF position and place a pad-

lock through the hole (see illustration below).

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

tagout guidelines.

Zero-Energy to Start-Up

KVAL 990-FX Service Manual

1-12

Zero-Energy to Start-Up

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

safety.

Start-up Guidelines

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

Inspect

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

Clean Up

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

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

Replace Guards

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

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

KVAL” on page 1-14.

Check Controls

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

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

Remove Locks

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

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

Perform Visual Checks

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

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

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

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

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

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

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

duration of the work.

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

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

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

without authorization.

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Kval 990-FX User manual

Kval 990-FX User manual

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