Kval 990-FX Operating instructions

Innovation, Quality & Honesty

Operation Manual

Published: June 7, 2023

990-FX Pre-Hanging Door System

Includes Machines with Array Hoppers and Machines with RTS Hoppers

990-FX Operation Manual

KVAL 990-FX 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 Technical Support at (800) 553-5825 or fax (707) 762-0485.

Manual Name: 990-FX Operation Manual

Manual Revision: 093-MV100.3, 093-MV100.4,093-MV100.4.1

990-FX is a trademark of Kval Incorporated.

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

Automation GmbH

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

For further information about this manual or other Kval Incorporated products, please contact us.

Mailing address:

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

Phone and Fax:

call: (800) 553-5825

fax: (707) 762-0485

General Office Business Hours

Mon-Thu:6:00 AM - 4:00 PM PST

Fri: 6:00 AM - 3:30 PM PST

Parts

Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web-

site at the “Contact Us” page.

email: [email protected]

KVAL 990-FX Operation Manual

Technical Support

For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact

Us” page.

Mon-Fri:4:00 AM - 4:00 PM PST

email: [email protected]

Field Service Support

For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the

“Contact Us” page.

email: [email protected]

Sales Support

For machinery information, specifications, and quotes. Call, email, contact us on our website at

the “Contact Us” page.

email: [email protected]

Kval Website

Learn about Kval, order parts, get information on our array of machines (including new machine

releases), learn about our machine software solutions, download machine documentation, view

videos of our machines in action, contact all the departments.

http://www.kvalinc.com

KVAL 990-FX Operation Manual

Revisions

June 7 2023: Page 2-5 to Page 2-6

Added mechanical back section three degree setup instructions.

Table of Contents

990-FX Operation Manual

Chapter 1 Introduction to the 990-FX

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

Metal Door and Jamb Machine.............................................................1-1

Table of Available Options ....................................................................1-2

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

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

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

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

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

Training.................................................................................................1-6

Protective Gear.....................................................................................1-6

When the Machine is Powered and Running........................................1-6

Lockout/Tagout Guidelines ...................................................... 1-7

Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-7

Lockout/Tagout Procedure....................................................... 1-8

Pre-Steps Before Lockout/Tagout.........................................................1-8

Lockout/Tagout Power ..........................................................................1-8

Lockout/Tagout Air Supply ....................................................................1-9

Start Maintenance.................................................................................1-9

Post Maintenance Steps.......................................................................1-9

Zero-Energy to Start-Up .......................................................... 1-11

Inspect ................................................................................................1-11

Clean Up.............................................................................................1-11

Replace Guards..................................................................................1-11

Check Controls ...................................................................................1-11

Remove Locks....................................................................................1-11

Perform Visual Checks .......................................................................1-11

Close the Cage Gate ..........................................................................1-12

Kval Return and Warranty Policy............................................. 1-13

Send the Item .....................................................................................1-13

Acceptance of Return .........................................................................1-13

Refund Turnaround Time ....................................................................1-13

Kval Errors..........................................................................................1-13

Customer Errors .................................................................................1-14

Shipper Errors.....................................................................................1-14

990-FX Operation Manual

Table of Contents

Warranty Replacement Parts..............................................................1-14

Getting Help from Kval............................................................. 1-16

Safety Sign-Off Sheet .............................................................. 1-17

A Note to the Operator........................................................................1-17

Chapter 2 Operation of the 990-FX

Initial Powering Operations for the 990-FX Line...................... 2-1

How to Power Up the Line....................................................................2-1

Home the 990-FX .................................................................................2-2

How to Power Down the Machine.........................................................2-3

Emergency Shutdown and Recovery ...................................................2-3

Mechanical Setup for Back Section 3 Degree Bevel ............... 2-4

Plate Width: Plate Router Vertical Travel..............................................2-4

Plate Router Depth ...............................................................................2-4

Adjust Plate Router to Zero-Degree Bevel ...........................................2-5

Machine Start Summary .......................................................... 2-6

Set-Up...................................................................................................2-6

Load Jamb and Clamp Jamb................................................................2-7

Load Hinges and Process the Door......................................................2-8

Description of User Interface Screens ..................................... 2-9

Screen Selection Menu Map.................................................................2-9

Machine Feed Back............................................................................2-10

About the Main Screen ............................................................ 2-11

Main Screen: 4 Carriage Head with Array Hopper..............................2-11

Main Screen: Carriage Head with RTS...............................................2-12

Machine Controls................................................................................2-13

Lock Group .........................................................................................2-16

About Manual Operation.......................................................... 2-18

Width Adjust........................................................................................2-19

Feed Manual Control ..........................................................................2-19

Lock Manual Control...........................................................................2-20

Hinge Manual Control.........................................................................2-20

Diagnostic Screen.................................................................... 2-22

About the Light Tower .............................................................. 2-24

Chapter 3 About the Setup Screen of the 990-FX

About Calibration ..................................................................... 3-1

Table of Contents

990-FX Operation Manual

Before you Calibrate.............................................................................3-1

Flow Chart of Calibration .....................................................................3-2

Enter a Positive or Negative Number ...................................... 3-3

Entering Calibration Offsets..................................................................3-3

About the Setup Screen........................................................... 3-4

Machine with RTS.................................................................................3-4

Calibration Steps for the Lock Location................................................3-5

Load a Known Good Door ....................................................................3-5

Adjusting Lock Location........................................................................3-6

Calibration of Timing: Front Section and Back Section.........................3-6

Calibration of Screw Shift .....................................................................3-7

Calibration of RTS Hoppers..................................................... 3-8

About the RTS Axis Direction ...............................................................3-8

Chapter 4 Tour of the 990-FX

Machine Component Terms..................................................... 4-1

Common 990-FX Line Layout.................................................. 4-2

Assembly Identification on Machine .....................................................4-3

Machine with an Array Hopper..............................................................4-3

Machine with RTS.................................................................................4-4

About the RTS ......................................................................... 4-5

Summary of the Controls on the Machine Line........................ 4-6

About the Operator Station...................................................................4-6

Descriptions of Machine Controls.........................................................4-7

Controlling Access to User Screens .....................................................4-7

Foot Pedal ............................................................................................4-8

Control Box...........................................................................................4-8

Hinges Loaded Button (Light Curtain Status Light) ..............................4-9

Safety Controls ........................................................................ 4-10

Emergency Shutdown and Recovery .................................................4-10

About the Light Curtain.......................................................................4-10

If the Beam is Broken .........................................................................4-10

To Resume Normal Operation after an Beam is Broken.....................4-11

About Gates Latches ..........................................................................4-12

Air Brake on 990-FX Screw Shooter...................................................4-12

About the In-Feed Section....................................................... 4-14

About the Front Section ........................................................... 4-15

Carriage Head Shifting Process .........................................................4-16

990-FX Operation Manual

Table of Contents

About the Hinge Carriage ........................................................ 4-17

About the Screw Shooter System............................................ 4-18

About the Hopper Operation...............................................................4-18

Hopper Process..................................................................................4-19

About the Screw Shooter Assembly ...................................................4-20

Six or Eight Screw Shooter (Hoppers on Machine) ............................4-20

Six or Eight Screw Shooter.................................................................4-21

About the Driver Assembly .................................................................4-22

About the Back Section ........................................................... 4-23

Front View of Lock Cutting Section.....................................................4-23

Back View of Rear Section .................................................................4-24

About the Out-Feed: ................................................................ 4-25

About the Electrical Panels...................................................... 4-26

Main Electrical Panel ..........................................................................4-26

Light Towers........................................................................................4-27

High Frequency Panels ......................................................................4-27

About the Nodes.................................................................................4-28

Example of Node Connections ...........................................................4-29

About System IT Administration............................................... 4-30

About the Machine Computer.............................................................4-30

Network Diagram................................................................................4-31

Backing up the Computer ...................................................................4-31

Procedure for Backing up Data...........................................................4-31

About Remote Connection to KVAL Service.......................................4-32

Option BC: Ball Catch.............................................................. 4-33

Option N: Dust Blow off System .............................................. 4-34

Option 8.0: Machine Accepts 8.0 Foot Doors .......................... 4-35

Option 8.0: About the Shift Function...................................................4-35

Option H: Securing Split Jambs............................................... 4-36

Option Z: Screw Changing Hoppers ........................................ 4-37

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.

TABLE 1- 1.

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 1-1

Safety! IMPORTANT safety information is described in this

section

page 1-5

Zero-Energy to Start-

Up

Procedure to power up your machine for the first

time.

page 1-11

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 1-16

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

machine.

page 1-17

Overview of the 990-FX Door Hanging System

1-1

Overview of the 990-FX Door Hanging System

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.

Standard three head option with

Hoppers affixed to the top of the

Screw Heads

Four Head special to accommodate

8 foot doors. Hoppers are ground

level for easy access. Bins allow

stocking of different colored screws.

Overview of the 990-FX Door Hanging System

1-2

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.

Three Head machine with the

Rotary Hopper stand. The Rotary

option allows kind change of screw

type with preloaded screws.

Overview of the 990-FX Door Hanging System

1-3

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.

Option Title Description

Overview of the 990-FX Door Hanging System

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.

2Operation

Interface

How to power machine line, and

operator interface descriptions.

3Tour of the

Machine

Highlights of the machine assem-

blies

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

2Maintenance Maintenance steps for the

machine line

3Troubleshooting Troubleshooting tips and theory

of operation.

Safety First!

1-5

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 1-17.

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.

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 Guidelines

1-6

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.

Note: Different versions of the stickers may have been applied to the machine. The

intent of safety is the same.

Training

Ensure that all employees who operate this machine are aware of and adhere to all safety precau-

tions posted on the machine and are trained to operate this machine in a safe manner. Figure 1-1

shows a sample of safety labels addressing training.

Read the Manual

FIGURE 1-1. Read the Manual Labels

Protective Gear

Never operate the machine without proper eye and ear protection. Figure 1-2 shows a sample of

safety labels addressing safety gear.

FIGURE 1-2. protective Gear Labels

When the Machine is Powered and Running

Serious injury or death could occur if these general rules are not followed.

• 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.

Lockout/Tagout Guidelines

1-7

Lockout/Tagout Guidelines

Follow these 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

1-8

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.

https://www.osha.gov/

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

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

lock on the handle in the extra holes provided.

4. Turn the Main Power on ALL electrical panels to the OFF position.

a.Lever style Electrical Panels: ensure the lever is in the down position, insert

lock and tag into the lever hole making sure the lever cannot move, lock as per

the tagout guidelines. (see illustration below).

Lockout/Tagout Procedure

1-9

b.Disconnect style Electrical Panels: push the red tab to pop it out. Place a pad-

lock through the hole. Place your tag on the padlock, as per the tagout guide-

lines below. (see illustration below).

Lockout/Tagout Air Supply

5. Turn all air valves to the OFF position and place a padlock through the hole (see

illustration below).

NOTE: Place your tag on the padlock, as per the tagout guidelines.

Start Maintenance

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

the machine to ensure equipment will not operate.

7. Maintenance or repairs may started.

Post Maintenance Steps

8. 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.

Insert Lock into hole.

Turn Switch to the

OFF position

Lock and Tag out

Lockout/Tagout Procedure

1-10

9. 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.

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

and the machine can be re-energized.

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

Zero-Energy to Start-Up

1-11

Zero-Energy to Start-Up

Starting the equipment properly is just as important as the Lockout/Tagout guidelines in terms of

safety.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 Technical Support. See “Getting Help from Kval” on page 1-16.

Check Controls

Confirm that all switches are in the “OFF” position. Please be advised that some components 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 operators are in a

safe place when the equipment is started.

Perform Visual Checks

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

personnel alarm before starting the equipment. If your operation is more complex, your com-

pany’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 maintenance 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.

Remember, Lockout/Tagout procedures work because you are the only one with the key to your

lock. Proper Lockout/Tagout can save lives, limbs, and money. Help make your work environment

safe for you and your fellow workers. Be sure to follow the P-R-O-P-E-R Lockout/Tagout proce-

dures, and that those around you do also.

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Kval 990-FX Operating instructions

Kval 990-FX Operating instructions

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