Page is loading ...
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.
Copyright 2014 Kval Incorporated. All rights reserved.
Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed
by Beckhoff Automation GmbH
Windows CE® is a registered trademark of Microsoft Corporation.
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 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
KVAL 990-H Operation 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-
ment to [email protected]. (NOTE: This is not a customer support email
link. For that, please refer to the Customer Service contact information above.) Thank
you!
http://www.kvalinc.com
KVAL 990-H Operation Manual
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.
/
