Kval 990-H Operating instructions

Brand: Kval

Model: 990-H

Type: Operating instructions

Innovation, Quality & Honesty

Operation Manual

: 6/7/16

990-H Pre-Hanging Door System

990-H Operations Manual

KVAL 990-H Operation Manual

Proprietary Notice

This Manual is confidential and contains proprietary information and intellectual

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

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

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

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

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

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

Manual Part Number: 137-OPDOC_990H-V2

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

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

by Beckhoff Automation GmbH

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

or sponsorship of Kval Incorporated.

Contacting KVAL

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

rated products, contact the Customer Support Department

• Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

• Phone and Fax:

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

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

• Business hours:

Technical Support:

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

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

Parts & Service Sales:

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

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

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

• Email: [email protected]

KVAL 990-H Operation Manual

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KVAL 990-H Operation Manual

Table of Contents

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 ............................................................1-4

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.......................................................................................1-15

Product Return Procedure..................................................................1-15

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

Operator’s Tour........................................................................ 2-2

The 990-H Process Summary ..............................................................2-2

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

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

Machine Components...........................................................................2-3

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

About the Operator Station...................................................................2-5

About the Foot Pedal and Control Box.................................................2-6

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

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

Programmable Hinge Applicator Position.............................................2-9

Programmable Hinge Locations ...........................................................2-9

990-H Door Hanging System

Programmable Door Index and Hinge Applicator Positioning...............2-9

About the Hinge Heads.......................................................................2-10

About the Six Shooter System............................................................2-11

About the Hopper................................................................................2-11

About the Six Shooter Assembly........................................................2-14

About the Driver Assembly.................................................................2-15

About the Back Section ......................................................................2-16

About the Out-Feed............................................................................2-18

About the Electrical Panels...................................................... 2-19

Electrical Panel Option: Servo Box 2..................................................2-20

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

About Switches and Sensors..............................................................2-21

Quick Start............................................................................... 2-23

Powering Operations for the 990-H......................................... 2-25

How to Power Up the 990-H...............................................................2-25

Home the 990-H .................................................................................2-26

How to Power Down the 990-H ..........................................................2-26

Emergency Shutdown and Recovery .................................................2-27

To Resume Normal Operation after an E-Stop...................................2-27

Safety Hooks ......................................................................................2-27

Description of User Interface Screens..................................... 2-28

Screen Selection Menu Map...............................................................2-28

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

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

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

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

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

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

Servo Jog Screen...............................................................................2-39

About the Calibration............................................................... 2-41

How to Enter Calibration Data............................................................2-41

Enter a Positive or Negative Number? ...............................................2-42

Main Cal Screen...................................................................... 2-43

Calibration Screen Descriptions .........................................................2-43

Setup Hinges 1-3 Screens..................................................................2-48

About the Pre-Drill Screen..................................................................2-52

Entering Pre-Drill Pattern Data...........................................................2-53

Diagnostic Screen.................................................................... 2-54

Checking the I/O of the 990H .............................................................2-55

About the Indicators............................................................................2-55

KVAL 990-H Operation Manual

Front Section I/O.................................................................................2-56

Front Section Servo I/O......................................................................2-56

Lock Section.......................................................................................2-57

Feed Section.......................................................................................2-57

Miscellaneous Sensors.......................................................................2-58

990-H Door Hanging System

Chapter 1 at a Glance

1-1

KVAL 990-H Operation Manual

CHAPTER 1 Introduction to the 990-H Door Hanging

System

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 Operation 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 application 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)

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

Overview of the 990-H Door Hanging System

1-3

KVAL 990-H Operation Manual

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

Overview of the 990-H Door Hanging System

KVAL 990-H Operation Manual

1-4

Options and Specials Available

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.)

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.

Overview of the 990-H Door Hanging System

1-5

KVAL 990-H Operation Manual

About this Manual

This manual is one of two manuals. The set includes this Operation Manual and Service Man-

ual.

The Operation Manual is directed toward operators of the machine. It includes identification of

machine assemblies, power-up and power-down steps, operation and using the user interface.

The Service Manual is directed toward qualified service technicians. It includes maintenance and

troubleshooting information.

TABLE 1.

Title Part Number

990-H Operation Manual 137-OPDOC_990H

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

Safety First!

KVAL 990-H Operation 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 Operation Manual

Electrical circuitry on this

machine is protected by an

approved lockable disconnect

circuit. In addition to this equip-

ment, you must install an

approved disconnect for the

electrical power supplying this

machine.

When opening the cabinet you must first turn off the

disconnect switch. When the cabinet door is open there

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

Some machines are powered by more than one supply

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

nance, lockout and tagout must be installed at all locations

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

formed by a qualified electrician.

Still has power

in OFF position

Electrical

Prior to performing any maintenance, repairs,

cleaning or when clearing jammed debris, you

must disconnect, tag out, or lock out the electrical

and air pressure systems. This should be done in

accordance with applicable state and/or federal

code requirements.

Before Conducting Maintenance

Laser Warnings

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

manufacturers safety precautions.

Safety First!

KVAL 990-H Operation 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 Operation Manual

Lockout-Tagout Guidelines

KVAL 990-H Operation 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 Operation Manual

Lockout Tagout Procedure

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

SB198 ruling of July 1991.

Use the following lockout procedure to secure this machine while it is

powered down. During a lockout, you disconnect all power and shut

off the air supply. Be sure to use the tagout guidelines noted below.

Pre-Steps Before Lockout Tagout

1. Evaluate the equipment to fully understand all energy sources (multiple electrical

supplies, air supply and pressure, spring tension, weight shifts, etc.).

2. Inform all affected personnel of the eminent shutdown, and the duration of the

shutdown.

3. Obtain locks, keys, and tags from your employer’s lockout center.

Lockout Tagout Power

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

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

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

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

below).

Power

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

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

Insert Lock into hole.

Turn Switch to the

OFF position Lock and Tag out

Lockout Tagout Procedure

KVAL 990-H Operation Manual

1-12

Lockout Tagout Air Supply

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

lock through the hole (see illustration below).

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

tagout guidelines.

Start Maintenance

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

the machine to ensure equipment will not operate.

8. Maintenance or repairs may started.

Post Maintenance Steps

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

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

and safety devices are installed.

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

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

re-energized.

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

and the machine can be re-energized.

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

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Kval 990-H Operating instructions

Brand: Kval

Model: 990-H

Type: Operating instructions

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Kval 990-H Operating instructions

Kval 990-H Operating instructions

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