990-FX Pre-Hanging Door System - KVAL | Door Machinery · Overview of the 990-FX Door Hanging...

Innovation, Quality & Honesty

Operation ManualPublished: January 16, 2020

990-FX Pre-Hanging Door SystemWith the RTS-FX Rotary Hopper System

Proprietary NoticeThis Manual is confidential and contains proprietary information and intellectual property of KVAL Inc., and i s 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: 093_OP_990FX_V6

The 990-FX Door Hanging System is a trademark of Kval Incorporated.Copyright 2019 Kval Incorporated. All rights reserved.

Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed by Beckhoff Automation GmbH

Windows 7® 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 KVALCustomer Service: For further information about this manual or other Kval Incorpo-rated products, contact the Customer Support Department

• Mailing address:Customer Support DepartmentKval Incorporated825 Petaluma Boulevard SouthPetaluma, CA 94952

• Phone and Fax:In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485Outside 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 Thursday6:30 AM to 1:30 PM Pacific Standard Time, Friday

Parts & Service Sales: 6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday6:30 AM to 1:30 PM Pacific Standard Time, Friday

(Other sales related inquiries: http://www.kvalinc.com) • Email: [email protected]

KVAL 990-FX Operation Manual

KVAL 990-FX Operation/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-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



Table of Contents

Chapter 1 Introduction to the 990-FXChapter 1 at a Glance.............................................................. 1-1Overview of the 990-FX Door Hanging System....................... 1-2

Hopper Options.....................................................................................1-2Table of Available Options ....................................................................1-3About this Manual .................................................................................1-4

Safety First!.............................................................................. 1-5Safety Sheet Sign-Off Sheet.................................................................1-5Safety Terminology of Labels................................................................1-5Safety Guidelines..................................................................................1-5

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

Lockout Tagout Procedure....................................................... 1-10Pre-Steps Before Lockout Tagout .......................................................1-10Lockout Tagout Power ........................................................................1-10Lockout Tagout Air Supply ..................................................................1-11Start Maintenance...............................................................................1-11Post Maintenance Steps .....................................................................1-11

Zero-Energy to Start-Up........................................................... 1-12Getting Help from KVAL........................................................... 1-14How to Download the Service Application ............................... 1-16

Download Application .........................................................................1-16Safety Sign-Off Sheet .............................................................. 1-19

A Note to the Operator........................................................................1-19

Chapter 2 Operation of the 990-FXAbout the Machine Line ........................................................... 2-2

Line System Process ............................................................................2-2Assembly Identification on Machine .....................................................2-3Photo of 990-FX and RTS-FX Setup ....................................................2-4About the RTS-FX ................................................................................2-4About the Jamb Transfer Machine........................................................2-5

Summary of the Controls on the Machine Line........................ 2-6About the Operator Station ...................................................................2-6Descriptions of Machine Controls .........................................................2-7Controlling Access to User Screens .....................................................2-7Foot Pedal and Control Box..................................................................2-8Hinges Loaded Button (Light Curtain Status Light)...............................2-9


Table of Contents
Safety Controls ........................................................................ 2-10
Emergency Shutdown and Recovery .................................................2-10990-FX Light Curtain...........................................................................2-10If the Beam is Broken .........................................................................2-10To Resume Normal Operation after an Beam is Broken.....................2-11Air Brake on 990-FX Six Shooter........................................................2-12

Tour of the Machine ................................................................ 2-13About the In-Feed Section ..................................................................2-13About the Front Section ......................................................................2-14About the Hinge Carriage ...................................................................2-15About the Six Shooter System............................................................2-16About the Six Shooter Assembly ........................................................2-18Driver Assembly..................................................................................2-19About the Back Section ......................................................................2-20Back View of Rear Section .................................................................2-21About the Out-Feed: ...........................................................................2-22

About the Electrical Panels...................................................... 2-23Main Electrical Panel ..........................................................................2-23High Frequency Panels ......................................................................2-24About the Nodes .................................................................................2-24Graphical Sample of Node Connections.............................................2-25

Options .................................................................................... 2-26Option BC: Ball Catch.........................................................................2-26Option N: Dust Blow off System .........................................................2-26Option: 8-0 Foot Door for FX ..............................................................2-27About the Shift Function .....................................................................2-27Option H: Securing Split Jambs ..........................................................2-28

Description of the Six Light Panel ........................................... 2-29Machine Start Summary .......................................................... 2-30Initial Powering Operations for the 990-FX Line ...................... 2-33

How to Power Up the Line ..................................................................2-33Home the 990-FX ...............................................................................2-34How to Power Down the Machine.......................................................2-35Emergency Shutdown and Recovery .................................................2-35To Resume Normal Operation after an E-Stop ...................................2-35

Description of User Interface Screens ..................................... 2-36Screen Selection Menu Map...............................................................2-36Machine Feed Back ............................................................................2-37

About the Main Screen ............................................................ 2-38Machine Controls................................................................................2-39


Table of Contents
Lock Group .........................................................................................2-42
About Manual Operation.......................................................... 2-43Jog Controls........................................................................................2-44Screw..................................................................................................2-45Carousel .............................................................................................2-45Lock ....................................................................................................2-45Feed....................................................................................................2-46

About the Setup Screen........................................................... 2-47Enter a Positive or Negative Number .................................................2-47Entering Calibration Offsets ................................................................2-48Calibration Steps for the Lock Location ..............................................2-49Lock Location Calibration ...................................................................2-49

Diagnostic Screen.................................................................... 2-53Door Count .........................................................................................2-54

Appendix: Machine Component Terms.................................... 2-55


Table of Contents


Chapter 1 at a Glance

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.


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 1-19

1-1


Overview of the 990-FX Door Hanging System

Overview of the 990-FX Door Hanging SystemKVAL'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.

Hopper Options

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.

KVAL 990-FX Operation Manual1-2


Table of Available Options

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

Option Title DescriptionOption C Pushbutton Selection for Face Bore

BacksetsFor 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.

Three Head machine with the Rotary Hopper stand. The Rotary option allows kind change of screw type with preloaded screws.

1-3

KVAL 990-FX Operation M
anual


About this Manual

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

Operation Manual includes the following:

Chapter Title DescriptionChapter 1 Introduction Descriptions of Machine Line and Safety

Information.Chapter 2 Operation Descriptions of how to power machine

line, and operator interface user screens.

Chapter Title DescriptionChapter 1 System IT Brief description of Computer and PLC in

the MachineChapter 2 Maintenance Maintenance steps for the machine lineChapter 3 Trouble Shooting Troubleshooting tips and theory of opera-

tion.

Service Manual includes the following:

K
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Safety First!

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 1-19.

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.

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

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0-FX Operation Manual

Safety First!

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

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Safety First!

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 powerin 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 WarningsOn some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions.

KVAL 990-F

1-7

X Operation Manual

Safety First!

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.

KVAL 9
90-FX Operation Manual1-8

Lockout-Tagout Guidelines

Lockout-Tagout Guidelines• Place a tag on all padlocks. On the tag, eachoperator must put their own name and date.(These locks are only to be removed by theperson who signs the tag)

• If more than one person is working on themachine, each additional person places a lockand tag on each disconnect.

• Only each operator may remove their ownlock 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 shutdownR ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)O...... OFF! Shut off all power sources and isolating devicesP...... Place lock and tagE...... ENERGY: Release stored energy to a zero-energy stateR ...... Recheck controls and test to ensure they are in the “OFF” state

1-9


Lockout Tagout Procedure

Lockout Tagout ProcedureThis 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

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Lockout Tagout Procedure

Lockout Tagout Air Supply

Start Maintenance

7. Once the locks and tags are in place and all personnel are clear, attempt to operatethe 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 alltools, spare parts, test equipment, etc., are completely removed and that all guardsand safety devices are installed.

10. Before removing the locks and tags, the person who attached them shall inspect theequipment to ensure that the machine will not be put in an unsafe condition whenre-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 thetagout guidelines.

1-11


Zero-Energy to Start-Up

Zero-Energy to Start-UpStarting 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.


Zero-Energy to Start-Up

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 procedures, and that those around you do also.Close the Cage Gate

Verify all cage gates are securely closed. Ensure all safety protocols are in effect.

1-13


Getting Help from KVAL

Getting Help from KVALBefore you seek help, first try the troubleshooting procedures. Follow the procedures below.

If you are unable to resolve the problem:

1. Locate the machine’s Specification Plate and record the serial number, 3 phase volts, electrical print number, and air print number.

2. Contact our customer support team:• 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• Email address is [email protected]• Hours:

6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday6:30 AM to 1:30 PM Pacific Standard Time, Friday

• What is the extent of the failure/reason for return? What are the relevant error mes-sages or error codes?

• How long did it operate?

Air Driven Machines

Pre -2019 Machines, look for the brass plate.

KVAL 990-FX Operation Ma1-14

nual

Getting Help from KVAL

• Did any other items fail at the same time?• What was happening when the unit failed (e.g., installing the unit, cycling power,starting other equipment, etc.)?

• How was the product configured (in detail)?• Which, if any, cables were modified and how?• With what equipment is the unit interfaced?• What was the application?• What was the system environment (temperature, spacing, contaminants, etc.)?

3. Call KVAL customer support for a Return Material Authorization (RMA). Whenyou call:

• Have the packing slip or invoice numbers available.• Have the documented reason for return available.

4. Send the merchandise back to KVAL.• Make sure the item(s) you are returning are securely packaged and well protectedfrom shipping damage

• Include the packing slip or invoice numbers.• Include the documented reason for return.• Include the RMA number with the parts package.

1-15


How to Download the Service Application

How to Download the Service ApplicationOn machines with Windows (8.1 / 8 / 7 / Vista / XP) and an internet connection, our service team are able to connect, run, and troubleshoot your machine by way of the operator station.

Download Application

.1. To download the application, go

the KVAL website (http://www.kvalinc.com)

2. At the KVAL website, select the Support tab. Follow the instruc-tions on the Support web page.

3. Click the Download button to download the application that allows the KVAL technician to have access to the operator sta-tion.

4. After the download is com-pleted, double-click the program icon.

Note: Web browsers have different methods of downloading programs. Below are samples of i.e Explorer and Google web browsers.

Sample of Google Browser: Located at the bottom left of the screen.

Sample of i.e Explorer: Located at the bottom of the screen. select the arrow and choose Save and Run



5. A pop-up window is displayed. Accept the request to run the program.

Note: Security settings may differ from plant to plant. If issues occur, contact your IT department.

6. The interface of the KVAL Support App will be dis-played. Enter your name in the Your Name field. The fields are described below:

Session code: An internal number to track this machine. It is auto filled.

Allow Remote Control: Program is ready to allow technicians to access machine computer

Your Name Field: Enter your name. The KVAL tech-nician will use this field to identify this machine.

Description: Enter machine Serial number and issue.

Indicator: Green indicates there is a good connec-tion to the service center. If red, there could be an

issue with a LAN connection. Check the connections in the plant.

7. After the KVAL Support App is loaded and completed, call the KVAL service center(1-800-553-5825) and have the technician con-nect to the machine computer.

8. Click the Allow button to give the KVAL service technician permis-sion to access the operator station.

We are now ready to troubleshoot.

1-17



Page Intentionally Left Blank


Safety Sign-Off Sheet

Safety Sign-Off Sheet Machine Model Number:_____________________________

A Note to the Operator

This machine can help you be highly productive only if you understand how to use it properly and follow the safe operating practices described in this document and the machine’s manual. If you do not understand the machine’s proper operation or ignore the safe operating practices, this machine can hurt or kill you. It’s in your best interest to safely and properly operate this machine.

Personnel Safety Concerns:

• I have been properly trained in the operation of this machine.• I will always wear ear protection when operating this machine.• I will always wear eye protection when operating this machine.• I will never wear loose clothing or gloves when operating this machine.• I will watch out for other people. Make sure everyone is clear of this machine

before operation.• I will always follow my company’s safety procedures. I have read and understand

these guidelines.Machine Safety Concerns:

• I have been given a tour of the machine and understand all the safety labels, E-Stops and the actions to take in case of an emergency.

• I will make sure all guards are in place before operation• I will turn off the compressed air, before loading hardware (staples, screws, etc)• I will turn off the electrical power, for setup• If the machine should operate in an unexpected manner stop production I will

immediately and notify a manager, a supervisor, or a qualified service technician.

I have read and understand this document and agree to operate this machine in a safe man-ner as described above.

EmployeeName (print):___________________ Signature: __________________ Date:____/____/____

Supervisor/Safety Officer/Trainer

Name (print):__________________Signature: __________________ Date:____/____/___

Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the KVAL website (http://www.kvalinc.com). You may also contact our Service Department at (800) 553-5825 or email at [email protected].

1-19


Safety Sign-Off Sheet


CHAPTER 2 Operation of the 990-FX

This chapter describes components, assemblies, and the user interface of the KVAL 990-FX Door Hanging System. The content is geared to help operators understand the basic operation of the 990-FX.


Section Name Summary Page

About the Machine Line General Information About The Machine Line. page 2-2

Summary of Machine Controls

Description Of The Machine Line Controls page 2-6

Safety Controls A Summary Of The Safety Controls On The Machine Line.

page 2-10

Tours of the Machines A Summary Of The Machine Assemblies page 2-13

Powering the Machine Line Instructions To Powering The Machine Line page 2-33

Descriptions of the Interface

Descriptions Of The Interface page 2-36

2-1

About the Machine Line

About the Machine LineLine System Process

The 990-FX will: • Cut a hinge pocket on a door and jamb for up to three hinges (Head Assembly)

• Drill pilot holes for the hinge screws (Head Assembly)

• Choose different screws with RTS-FX.

• Apply up to three hinges.(Six Shooter)

• Attach the hinges with screws (Six Shooter)

• Cut a lock and lock plate (Back Sec-tion)

• Is Controlled by a Central Opera-tors Station

The Jamb Transfer will: • Feed a jamb back to the operator to load into the 990-FX

• the feeding is synchronized with the 990-FX process.

• The Jambs are fed by customer sup-plied machine.

• An Out-Feed table is included• Opt Includes a Reverse Feed (Mirror Footprint)

The RTS-FX is:• A companion station for the 990FX allowing up to three sets of screw hoppers to automati-cally index for screw color change.

• Three sets of screw hoppers to rotate in 90 degree increments controlled by a servo motor and gear system.

• Screw feed hoses (18) from the 990FX screw drivers are arranged to connect to a manifold below the screw hoppers. Screws drop by gravity from the hoppers down into the manifold, and are blown with compressed air up to the screwdrivers.

• Screws can be easily reloaded into the hop-pers when rotated in alignment with the hinge side of the 990FX.



Assembly Identification on Machine

Electrical Panel # 1 Out-Feed

Operator’s Station

Hopper B

Hopper A

Front Section

Back Section Six Shooter 2

Six Shooter 3

In-Feed

Hopper C

Opt: Ball Catch (X2)

Lock Bore Assembly

Six Shooter 1

Carriage Head 3

Carriage Head 2

Carriage Head 1

Air Tank

RTS-FX

Customer supplied Feed Table

Jamb Transfer

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90-FX Operation Manual


Photo of 990-FX and RTS-FX Setup

Below is a photo of the In-Feed area of the Production Line.

FIGURE 2-1. 990-FX and RTS-FX

About the RTS-FX

The RTS-FX Hopper sets are designated by Letters A, B, and C. Different screw colors can be loaded into each hopper set. Each set of Hoppers can be activated through the user interface screen.

After activated, the Hoppers rotate to the loading position. Screws will drop into the manifold and are blown with compressed air up to the screwdrivers.

RTS-FX

Screw Transfer Hoses990-FX

Note: Feeder not shown.

Jamb Feeder



FIGURE 2-2. Rotary Hopper

About the Jamb Transfer Machine

FIGURE2- 3. Jamb Transfer

Hopper Sets. Labeled A, B, and C.Select the Hopper set at the Operator’s Screen.

Motor Assembly and Rotate Gear Assembly

Air Solenoid Bank

Manifold (Not Shown)Adjustable air pressure to drive screws to Hopper

Jam

b Fe

ed

The Jamb Transfer will: • Feed a jamb back to the operator to load into the 990-FX

• the feeding is synchronized with the 990-FX process.

• The Jambs are fed by customer supplied machine.

• An Out-Feed table is included• Opt Includes a Reverse Feed (Mirror Footprint)

990-FX

Door Feed

2-5


Summary of the Controls on the Machine Line

Summary of the Controls on the Machine LineThis section describes the controls located on the machine line.

About the Operator Station

FIGURE2- 4. System Operator Station

Touch Screen Interface: Main Control of the 990-FX. Auto load and run predetermined parameters on doors. Manually control the door path and pro-cess through the line. Machine diagnostics are included, as well as internet support and connectiv-ity for remote support via our Service Support.

Main Control Panel: Power -Up and Power Down machines. Start and stop the door pro-cess.See “Tour of the Machine” on page 2-13

Main Control Panel: Power -Up and Power Down machines. Start and stop the door pro-cess, pause doors in the Feeder and Stacker. Emergency Stop.See “Tour of the Machine” on page 2-13

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Descriptions of Machine Controls

On the Main Control Panel, each machine has a Control Transfer Switch a Start and Stop button. This section contains descriptions of other mechanical controls associated with the machine con-trol set. For detailed information about the start-up process, see “Tour of the Machine” on page 2-13

Controlling Access to User Screens

This Machine Line has the ability to lock out changes to certain parameters such a presets and cal-ibrations.

Note: Locked out parameters may vary due to customer design wants.

Start Machine Button: Wakes up the machine, similar to a boot-up

Stop Machine Button: Puts the machine to sleep

Control Transformer: Energize and De-Energize the machines

Lock: Lock out access to Adjust-ment

E-Stop: push to shut down machine in an emergency situa-tion.

To allow the operator to make changes to parameters, turn the Set Up Lock to the On position. When this key is in the Off position, the parameters are locked out. No changes to the parameters may be made in the off position.

The key may be taken out in the off position, to prevent any inadvertent changes to the cut parameters.

Set Up Lock

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Foot Pedal and Control Box

The control box is located near the center six shooter on the front section of the machine. Includes manual controls of the Jamb Clamp, RH or LH orientation, and six shooter operation.

Door Clamp Pedal: The door clamp pedal activates the door clamp to either clamp or unclamp the door. Can be used in manual mode to posi-tion a door. Press once to clamp, press again to unclamp.Jamb Clamp Pedal:The jamb clamp pedal activates the jamb clamps to clamp the jamb in place. or to unclamp a jamb. Press once to clamp, press again to unclamp.See “Machine Start Summary” on page 2-30.

Door Clamp / Un-Clamp

Jamb Clamp / Un-Clamp

Foot Pedal

Control BoxStart Sequence: Press to start the door sequence that was pre-selected by the operator via the touch-screens. Push when jamb is loaded and clamped properly, hinges have been loaded, and hands are safely out of the way.Note: Be prepared for the front section routers to move into position and begin routing, as well as the back section routers, lock bore, and bolt drill. The Six-Shooter heads will also begin to move into position.

Door Auto RH / LH: Press for Auto Run, or to receive either a left-hand or right-hand incoming door. When in “Auto Door” mode, the 990-FX receives information about the incoming door from the incoming machine.

Unclamp: Use this button when performing a manual door run to unclamp the door after machining is complete. If you are performing an auto run and have activated the “Auto Unclamp” button on the auto run touchscreen, then pressing the 990-FX control box “Unclamp” button is unnecessary.

Emergency Stop: The red emergency stop button halts machine operation; it does not kill electrical power in the machine. Important: If, at any time, the operator must work on or enter the machine for any reason, shut off electrical power and properly lock- and tag-out the machine to remove electrical energy from the machine. If a problem occurs during operation, push the emergency stop button.

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Hinges Loaded Button (Light Curtain Status Light)

The Hinge Loaded button is located on the Light Curtain frame.

Hinges Loaded: Step out of the Safety Light Curtain and press this button after hinges are loaded on to the Hinge Applicators.The Light Curtain will be activated.

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VAL 990-FX Operation Manual

Safety Controls

Safety ControlsEmergency Shutdown and Recovery

Depending on the model of machine, there are emergency shutdown (E-Stop) switches located at key points around the machine.

The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.

When an E-Stop switch is activated, high voltage power is cut to the machine. The motors will stop but power to the PLC and the Operator Sta-tion Screen will remain on.

Note: The machine responds in the same way if you press the STOP button on the operator's station.

To Resume Normal Operation after an E-Stop

If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved:1. De-activate the E-Stop switch by pulling it out. 2. Push the START MACHINE button on the operator's station3. Press the Reset Light Curtain Buttons on the Feeder and Stacker

990-FX Light Curtain

The Safety Light Curtain provides safety for personnel who enter the defined area when the machine is active. If any part of an operator’s body is detected in the defined area, the machine stops the operation.The machine must be reset from the operators station to continue machining.

The Safety Light Curtain is composed of an EZ-Screen emitter and receiver. The emitter has a row of synchronized light-emitting diodes (LEDs) that send signals to the receiver. The receivers have a a matching row of synchronized photo detectors that read the signal from the emitter. When the signal is blocked of any beam, the machine stops. To continue machining push the Start button

Important: The EZ-Screen system is aligned at the factory. Do not move the emitter or receiver modules. This may cause misalignment, if the system is mis-aligned the machine will not start

If the Beam is Broken

If the beam is broken, the machine will shut down. This is safety feature performs the same func-tion as an Emergency Shutdown (E- Stop). For information on the E-Stop function, see “Emer-gency Shutdown and Recovery” on page 2-10


Safety Controls

FIGURE2- 5. Operation of Safety Curtain

To Resume Normal Operation after an Beam is Broken

If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved:

Status Indicator and Hinges Loaded (Reset)

Breaking of any beam stops the machineMachine in operation

Emitter

Receiver

2-11


Safety Controls

Air Brake on 990-FX Six Shooter

The 990-FX has air brakes on the Six Shooter assemblies. The brakes will lock the six shooter in place avoiding a crash to the head. The brakes are controlled by a lack of air pressure and will lock when the air pressure drops below a reference level.

11. Push the START MACHINE button on the operator's station

2. 3Press the Hinge Loaded Button.

3. Home the Machine

2

Brakes are located on each side of the six shooter assemblies

Bypass valve will bypass air causing the brakes to lock

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Tour of the Machine

Tour of the MachineThis section identifies assemblies and parts on the machine.

About the In-Feed Section

At the In-Feed, the door is fed in the machine. Sensors detect the door and start the auto feed and clamping of the door.

• Door is input from previous machine• Includes automatic door width adjustment• Door is feed through machine for processing • The door is automatically positioned while the operator loads and clamps the jamb.

FIGURE 2-6. Key Assemblies on the In-Feed Section

Lock Back SectionFaceplate routing and boring for lock and bolt

In-Feed SystemDoor is delivered from previous machine and fed into 990-FX for process-ing.

Hydraulic Tanks for Six ShootersSupplies hydraulic pressure to operate Six Shooter.

Six ShootersAuto drop down to apply hinges and secure them with screws delivered from Hopper

Six Shooter NodesWiring for PLC con-trol. Includes output and Input signals One node per Six Shooter

Frame NodeLocalized Electrical Box

Out of Pocket SensorA through beam that senses if the Router car-riage is out of the pocket.

In Pocket Sensor:A through beam that senses if the Router car-riage is in the pocket

2-13


Tour of the Machine

About the Front Section

As the door is processed the Front Section performs Jamb and Hinge machining. Simultaneously, the Back Section performs lock and faceplate machining. The Front Section performs the follow-ing:

• Door is fed in and positioned from In-Feed• Jamb is placed into Jamb Holder and clamped into place• Carriage Heads rout hinge pockets on jamb and door edge• Carriage Heads pre-drill pilot holes for Hinge application• Hoppers deliver screws to Six Shooters• Six Shooters drop down and drill hinge into place on jamb and the door edge.

FIGURE 2-7. Front Section

Carriage Head #1 Carriage Head #2 Carriage Head #3

Screws Transported

Six Shooter #1 HoppersSix Shooter #2

Six Shooter #3

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Tour of the Machine

About the Hinge Carriage

There are three Hinge Carriages on the front section. Each carriage includes:

• A router to automatically rout a hinge pocket on the door and jamb. • A pre-drill to drill pilot holes in the hinge pockets to ready the insertion of screws by the six shooter

FIGURE 2-8. Hinge Carriage Parts

Pre-Drill: Drills pilot holes for insertion of screws on the jamb and the door. Air Driven.

Router: Routs the hinge pocket on the jamb and the door at the same time as the counter rotate router.

Pre-Drill

Router

Door Predrill Bits

Jamb Predrill Bits

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KVAL 990-FX Operation
Manual

Tour of the Machine

About the Six Shooter System

There are three Six Shooters on the front section. The six shooters work with Dual Hoppers that deliver the screws to the machine. The six shooter system includes:

• A separate bank of Hoppers to allow easy switch over to different colored screws or switch over to reload.

• Three Six Shooters that deliver the hinge to the hinge pockets and then attaches them with six screws on the jamb and the door.

The Hopper Rotary Bank (Option)Hoppers deliver the screws to the six shooters indicated below.About the Hopper

Review to the figure below for identification of Hopper assemblies. See “Hopper Pro-cess” on page 2-17 for operation descriptions.

FIGURE 2-9. Hopper Part Call-Outs

Screw Track-ing Plate Assembly

Gate Assembly Hopper Quick Change Dump Gate

Quick Change Dump Container

Hopper Cylinder

Screw Delivery Tubes Air Injected Plate Assembly

Cylinder

Screw Pick Off Slide Assembly

Screw Pick-Off Cylinder

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Tour of the Machine

Important: Do not adjust any of the Hopper air cylinders. They are adjusted at the fac-tory. Any adjustment may cause timing issues with the operation of the Six Shooter. If you think problems are being caused by the cylinders, please contact the KVAL Service Department for direction.

Hopper Process

1. Pour Screws into the Hopper. Note: The recommended maximum amount of screws a quantity of 600.2. The Hopper moves up and down periodically during the process by the Hopper Cyl-

inders to organize the screws and deliver them to the Screw Tracking Plate.3. The Gate Assembly monitors the quantity of screws delivered to the to the Screw

Tracking Plate Assembly.

6. Press Hinges Loaded on the Six Shooter Control panel to activate the Slide Assem-bly to drop the screws into the Screw Delivery Tubes.

7. Each tube has air injectors to speed the delivery to the Screw Receiver Tubes. Quick Change ProcessSome Six Shooter Systems have an a quick change option to quickly change to differ-ent colored screws. To start the quick change process:8. Press the Load button on the Touch Screen.

Important: Do not put Magnetized Screws in Hopper. Magnetized screws can cause sluggish response to screws getting stuck. Hopper plates could get magnetized and will have to be demagnetized with a degausser.

4. The screws are stacked in the slots of the Screw Tracking Plate Assem-bly.

5. The Screw Pick Off Cyl-inder moves the Slide Assembly to capture screws six at a time.

2-17


Tour of the Machine

The back section of the Hopper will cycle upward once to shift all the screws from the back door to clear screws between the back door of the hopper and the slides.

9. Once the Hopper is in the up position, the door will open and the Hopper will cycle down quickly to throw the surplus of screws out the funnel container.

10. Once in the back section is in the down position, the front section (Screw Tracking Assembly) moves upward to drain the rest of the screws out of the hopper this will cycle one more time to clear the screws from the slides.

11. Press the Reset button on the Six Shooter panel located mid machine on the front section.

12. Fill the Hopper with new screws.About the Six Shooter Assembly

Settings for the Six Shooter assemblies are entered in the User Interface. Door is automatically positioned while the operator loads and clamps a hinge jamb. Routing and boring occur while the operator places hinges into the nests of the hinge applicators.

FIGURE 2-10. Six Shooter Call-Outs

Horizontal Rails. Allows the Six Shooter to the move to the side for Maintenance and Manual application of Hinges

Vertical Rails:

Tubes: Delivers Screws to Hinge Applicator by way of plas-tic tubes.

Driver Assembly:

Hinge Application:

Vertical Cylinder: Drives Six Shooter Up and Down

Spring: Tension for vertical movement

Note: Air brakes are located on the vertical rails. The brakes will operate when air pressure goes down a set reference level.


Tour of the Machine

Driver Assembly

The Driver Assembly is the work horse of the Six Shooter. The assembly automatically receives, aligns, and drives the screws into the door and the jamb.

FIGURE 2-11. Six Shooter and Gear Box Call-Outs

Split Shells X6:Receives 6 screws, straight-ens, and aligns them.

Hinge Indexer X2:Factory set to align hinge.

Magnets:Four Magnets hold Hinge for Application.

Index Spacers X2:Factory set to align hinge.

Screw Receiver Tubes:These tubes receive the screws from the hopper by way of plastic tubes

Latch Arm:Latches to H Block to secure in place.

Latch Arm Cylinder:Moves latch arm in and out of position

Air MotorGearbox:Geared to drive 6 screws simultane-ously

Chucks X6:Holds 6 screws aligned to the Door and the Jamb.

Hinge Applicator:Location to attach Hinge

Turret to Adjust Depth:Adjustable stops to set the depth of the screw drivers. Used with the Forward Limit Switch.

*Forward Stop Limit Switch*Reverse Stop Limit on other side

Plunge Cylinder: Moves the screw drivers into place

2-19


Tour of the Machine

About the Back Section

As the door is processed the Back Section performs lock and faceplate machining. Simultane-ously, the Front Section performs Jamb and Hinge machining The Back Section performs the fol-lowing:

• Works in partnership with front section process• Includes faceplate routing• Includes boring for lock and bolt.

Front View of Rear Section

FIGURE 2-12. Key Assemblies on the Back Section (View from Front Section)

Back Section Valve Bank

Lock Bore Motor and Drill: Drills locks holes on the face of the door

Chip Out Loca-tion: Lock Bore

Bolt Drill Motor Machines Hole for Bolt

Self Centering ‘X’ axis: Cen-ters the Bolt drill in the ‘X’ axis.

Bolt Drill Extend and Retract Cylinder


Tour of the Machine

Back View of Rear Section

FIGURE 2-13. Key Assemblies on the Back Section (Back View)

Bolt Drill Extend and Retract Cylinder

Oil ReservoirLock Bore Extend and Retract Cylinder

Lock Bore Limit Switches

Face Plate Motor and Drill: Routs face plate.

Edge Clamp: Clamps edge of door

Edge Clamp: Clamps edge of door

Deep

Shallow

Retracted

2-21


Tour of the Machine

About the Out-Feed:

• The door is automatically positioned to be fed into the next machine• Sensors detect when to send out door.

FIGURE 2-14. Key Assemblies on the Out-Feed Section

Opt: Dust Collection Blow -Off Nozzles

Valve Bank

Back Section

Air Input System

Out-Feed SystemThe processed Door is fed to the next machine. Sen-sors detect position of door and when to send it out.

Hydraulic Tanks for Six ShootersSupplies hydraulic pressure to operate Six Shooter.

Front Section

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About the Electrical Panels

About the Electrical PanelsWarning: High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off. If working on the panel, follow safety protocol as described in Chapter 1.

The 990-FX has a Main Electrical Panel and a High Frequency Panel. Below is an overview of the location of assemblies in the panes

Note: Component layout in the Panels may vary. Essentially the operation is the same.Note: Some Options may include a Main Power Distribution Panel. This panel accepts

factory power and distributes to the Main Electrical Panel and the High Fre-quency Panel. See your machine schematics tor more information.

Main Electrical Panel

The Main Electrical Panel:

• Supplies voltages to the machine • Contains the PLC (Programmable Logic Controller)• Contains servo drives to interact with the servo motors (Axis and Lock Location) in the front and back sections

FIGURE 2.15 Main Electrical Box Overview

PLC with Inputs /Outputs

Ethernet Dist. Block

Power Supplies

24VDC and 120Vac Terminal Block

High Voltage Section• Disconnect• PDR • Fuses

Servo Drive

Lock Carriage

Option: Infeed Shift

Option Outfeed Shift

Control Transformer

2-23



High Frequency Panels

The High Frequency Panel

• Supplies voltages to the machine • Contains the PLC interface• VFDs (Variable Frequency Drives) to interact with hinge and faceplate routers, width adjust motors, and feed motors

FIGURE 2-16. Overview High Frequency Panel

About the Nodes

Nodes are interfaces from the Main E Box. Node contain inputs and outputs of PLC and power connections. For example, door sensors, width adjusts, and tool interfaces.

VFD Section• Hinge Routere(1-4)• Face Plate Router• Feed Motor• Width Adjust

PLC Interface

120Vac / 24 VDC Terminals

Input / Output Terminals High Voltage Section

• Disconnect• PDR • Power Dist Connector• Fuses

Contactors and Thermal Over load Circuits

• Lock Bore• Screw Drivers(1-4)• Bolt Drill

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L 990-FX Operation Manual2-24


FIGURE 2-17. Sample of a Frame Node

Graphical Sample of Node Connections

Refer to the machine’s electrical schematics for detailed information

FIGURE 2.18 Location of Nodes on Machine

PLC InterfaceTop Ethernet cable is from PLCBottom Ethernet goes to Cutter Node

Inputs and Outputs

Interconnect Bar

Main E Box:Contains Servo Drives

Network Connections, power, and Inputs/Outputs originate from this box and are connected to Nodes.

Network Connections

Power Distributed to Points in the machine

High Freq Box

Power Distributed to Points in the machine

Frame Node

Screw Driver 1

Screw Driver 2

Screw Driver 3

Screw Driver 4

Back Section Node

2-25


Options

OptionsThis section describes some of the common options offered by KVAL. Your machine may not have these options.

Option BC: Ball Catch

Drill assemblies are mounted onto the lock boring section for drilling left hand and right hand doors for drive-in ball catches. When selected the proper drill automatically pivots in to drill into the top of the door. minimum door width for drilling is 18".

FIGURE 2.19 Location of Ball Catch Drills

Option N: Dust Blow off System

Air blow-off tube cleans dust and chips from the top of a door. Located on the Outfeed of machine.

FIGURE 2.20 Air Blow off

Front of Machine

Ball Catch Left Hand Door

Ball Catch Right Hand Door

Blow off Bar

Air Source


Options

Option: 8-0 Foot Door for FX

Includes the following additions.

• Additional Hinge Router• Extended Frame for 8/0 Capability• Servo Screw lock back section modification for 8-0 application• Extra Door Stop for 8-0 doors• Air Cylinder for Hinge Router Shifts for 6-8 & 8-0 • Retractable Six-Shooter for loading in jambs (servo motor driven)

About the Shift Function

The Shift In Function moves Car-riages 1,2,3,and 4 into working posi-tion

Shift In

Shift OutThe Shift Out Function moves Car-riages 1,2,3,and 4 into a position to allow the operator into the machine processing area. Allows the operator to insert the jamb into the machine.

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KVAL 990-FX Operation Ma
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Options

Option H: Securing Split Jambs

This option includes two crown staple guns that are mounted onto the jamb clamp brackets.

When activated, staples will be driven into the back side of the split jamb to keep the male and female together. This will keep the split jamb secure when feeding to the 700C.

The staple guns are fired with a single valve that is interlocked with a safety switch to disable the staple guns unless there is a jamb clamped in the machine.

To Use this Function:

1. Enable by selecting the Split Jamb Stapler button (Green).Located on the Main Screen.

2. Load the male split jamb into the female slot of the jamb.

3. Load jamb assembly into machine.4. During process, The split jamb will auto trigger the fir-

ing mechanism of the staple gun.Note: The nail gun will not fire unless the enable button

is activated on the Operators Screen and the safety switches are activated by the male split jamb.

Staplers

KVAL 990-FX
Operation Manual2-28

Description of the Six Light Panel

Description of the Six Light Panel The six lights on this panel indicate the status of the Commander III system.

The Sequence that the lights activate is as follows:1. Control Power2. Overload Relay3. E-Stop4. Stop 5. Start6. 24VDC

2-29


Machine Start Summary

Machine Start SummaryThis is a summary of the start sequence for the 990-FX Line.

Ensure factory air and power is present at the machine. For more information: See “Tour of the Machine” on page 2-13

1. Ensure the machine main Air Supply Valve is on.2. Turn on the Red Power Lever at each Electrical Panel.3. Turn on each Green Control Transformer Lever on the Operators

Station.

After the computer is completed booting up, the Interface will start automatically.

However, for instruction purposes, below are manual steps to start the programs

Double Click the desktop icon.

Press the Hinge Loaded button to start the pro-cess.

Select the Home Machine Line Button. After all machine is Homed, the machine status will display Idle in the Machine Feedback Status box.



Select the correct Preset. Verify that the information is correct. For Example: Check Door Width, Check Auto Feed is enabled, Auto Width is enabled, Check Jamb Pusher is Enabled, and Auto Door Width is Enabled.

After the machines have the Home sequence and door is fed in and auto-clamped, perform these steps.While loading the jamb, it is important to be mind-ful of the placement of your hands. If hands are in the wrong place when the jamb is being loaded, the jamb clamp could crush hands.

1. Pull jamb from Jamb Transfer Machine

2. Load Jamb on top of ledge pressing tightly against fence.

3. After Jamb is secure, press the Jamb Clamp Foot Pedal to clamp the Jamb

Caution: Pay Atten-tion to the Hand Place-ment and Warning Stickers on the Machine.

2-31



4. .Press the Start Sequence button.

5. Load the hinges, one for each of the three Six-Shooter heads with the hinge pin towards the top of the door. Each of the three Six-Shooter heads has a hinge pocket in which to place one hinge. The hinge pocket is magnetic and will hold the hinge in place

6. Move out of area beyond the Light Curtain

7. When outside of Light Curtain, press the Hinge Loaded button to start the process.

8. Repeat from Step (Load Jamb) until completed.

Take Note of the Status Blink codes


Initial Powering Operations for the 990-FX Line

Initial Powering Operations for the 990-FX LineThis section describes how to power up and to power down the 990-FX Line.

Powering up the system includes:

• Applying power to the entire system• Starting the Control Circuit

Powering down the system includes:

• Shutting down the control power• Removing power from the entire system

How to Power Up the Line

1. Ensure factory air is applied to each machine and main air supply is turned on.2. Check that all E-Stop buttons are out and safety gates are closed.Note: A pop-up is displayed on the user screen if an E-Stop is pressed. The pop-up will

indicate which E-Stop has been activated

3. Make sure the electrical disconnect each electrical cabinet is turned to the ON position.

4. Switch the green Control Circuit switches to the ON positions. They should light up5. Push the green Start Machine buttons to “boot up” the machines. Note: Boot up may take 2 to 3 minutes.

Control Circuit Switch Start Machine

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X Operation Manual


Home the 990-FX

The 990-FX must go through a homing routine before any operations are performed. The homing routine sets a zero reference from which the 990-FX measures its movement and cutting process.

If power is lost or the 990-FX is re-set, the homing routine must be performed again to reset the zero reference

Press the Home button on the Main Screen touch screen.

6. Initiate the Hinge Loaded to act as a Reset. Note: This process is a safety precaution to ensure the no personnel is in the machine

staging area.

Push the Hinge Loaded Button

7. All lights on the status light panels on the electrical box should be illuminated.

Note: If a status light does not turn on during the power up process, see the trouble shooting chapter in the Service Manual.

1. The machine will move to the home position at the in-feed end of the machine.

2. The machine will then move to about the middle of its travel.

The 990-FX is now ready for work.



How to Power Down the Machine

1. Push the Stop button for each machine, located on the Operator’s Station

2. Shut down the operating system, by selecting Shutdown from the Desktop.

Note: Make sure Windows is shutdown completely before turning off the machine. Hard drive or data may be dam-aged if not turned off in this order.

3. Switch the green Control Circuit switches for each machine to the OFF position.

4. KVAL also recommends that you turn the disconnect switches on the electrical cabinets to OFF; this helps reduce possible damage resulting from power surges from electrical storms.

Emergency Shutdown and Recovery

There are emergency shutdown (E-Stop) switch located at key points around the machine.

The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.

When an E-Stop switch is activated, power to the machine is killed.

The machine responds, in the same way, if you press the STOP button on the operator's station.

To Resume Normal Operation after an E-Stop

If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved:

1. De-activate the E-Stop switch by pulling it out. 2. Push the Start Machine button on the operator's station3. Home the Machine.

1

2

3

2-35


Description of User Interface Screens

Description of User Interface ScreensThis section describes the user interface screens. The user interface allows the operator to use a touch screen to control the door cutting process, auto-run, manually run the door, store door pro-files, and use diagnostics to help troubleshoot the 990-FX.

Screen Selection Menu Map

Below are the menu selections for the 990-FX.

.

FIGURE 2-21.

Main Menu: Opening Screen. Set Presets to machine the doors.See “About the Main Screen” on page 2-38.

Manual Menu: Control the machine manually through this screenSee “About Manual Operation” on page 2-43.

Setup Screen: Calibrate the position of the lock location See “About the Setup Screen” on page 2-47.

Diagnostic Screen: Observe the history of the machine operations. Error messages can be seen here for troubleshooting See “Diagnostic Screen” on page 2-53.

KVAL 990-FX Opera2-36

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anual

Description of User Interface Screens

Machine Feed Back

At the top and at the bottom right hand cor-ner of all user screens is status feedback information. The information generated is as follows:’

1. General Machine Status2. Front Section Status 3. Back Section Status4. Current Servo Positions

Note: Use this information to isolate issues if having problems with the machine.

1

2

3

4

2-37


About the Main Screen

About the Main ScreenThe Main Screen is also the startup screen for the 990-FX. From this screen, all the basic user interface controls are available to run a door.

FIGURE2- 22. Main Screen



Machine Controls

This button starts the home sequence on the machine, which causes the movable fence to slowly scan to find a physical reference point on the frame. When this point is found, the position is stored and then used to calculate the location of all moves after this. The home sequence must be performed every time the machine is powered up or reset.

If a fault occurs that cannot be cleared, press the Reset but-ton. This button will reset the machine to the start position before homing. Note: Press Home Machine after Reset Machine

This button stops the door in the process.

This button shuts down the computer. Use this button as part of the shutdown pro-cess.See “Initial Powering Operations for the 990-FX Line” on page 2-33

This button shuts down Interface Program and defaults to the Windows Desktop

Home Button

Reset Button

Stop Sequence Button

Shut Down Button

Exit Application Button

2-39



Auto Modes

From these buttons you can toggle auto functions on or off. Auto Feed: Press Auto Feed to toggle the auto feed on or off. In auto mode, the feed system will bring in and clamp a door, wait for pro-cessing to complete, then feed the door to out.Feed Through: Press Feed Through to toggle the feed through on or off. In feed through mode, the door will pass through the machine without processing.Auto Unclamping: Press Auto Unclamping to toggle auto Unclamping on or off. The auto unclamp button sets the machine to automatically unclamp the door after machining is completed.

Door Spec Group

Set the parameters for the door in the Door Spec group. The set-tings include:• Preset in Use: Displays the name of the preset setting that is running.

• Width: Displays the width of the door in process.• Jamb Pusher: push to enable or disable the Jamb feed from the Jamb Feeder

Preset Selection Button Group

Pressing a preset button, calls one of twelve pre-sets stored in memory. Pressing the Modify Preset button allows the operator to store the active Main Screen parameters. After pressing the Modify Preset button:1. Select one of the gray buttons in which to save the parameters2. Name it to an appropriate label. 3. Select the save button to save to memory.



Head 2 Router \ PredrillInitiate for 2 Hinge doors• Routers: Press to Enable or Disable the Routers in Head 2• Predrills: Press to Enable or Disable the Predrills Head 2

Hinges Group

Set the parameters for the hinges in the Hinge Spec group. Push desired buttons to select specification or toggle state.Hinges• Hinges: Press to Enable or Disable all the Hinges.• Routers: Press to Enable or Disable the Routers in all the Hinges

• Predrill: Press to Enable or Disable the Predrills in all the Hinges.

Jamb Transfer Buttons• Jamb Transfer: Press to Enable or Disable the automatic delivery of the Jamb from the Jamb Transfer machine.

• Manual Jamb Transfer: Press to Enable or Disable the Manual Jamb Transfer

Hinge Modes (Screws)

From these buttons you can toggle auto functions of the screw functions of the Hoppers.Screw Controls• Screws: Press to Enable or Disable all Screw pickup.• Screw 1-3: Press to Enable or Disable Screw pickup for individual Hoppers.

• Screw Type A, B, or C: Press to Enable or Disable the Screw types that are loaded in pickup bins.

• Screw Drop Press to Enable or Disable the Screw Drops for all Six Shooters.

2-41



Settings include:• Lock: Press the Lock button to enable or disable the lock section machining process. If disabled, the back section will not machine the door

• Lock (#1-3): Set the lock position.• Lock Bore: Press the Lock Bore button to enable or disable the Lock Bore• Bolt Drill: Press the Bolt Drill button to enable or disable the Bolt Drill.• Face Plate: Press the Face Plate button to enable or disable the Face Plate.• Lock Backset: indicates the backset distance for the each downloaded preset.• Ball Catch (Option): Press to Enable or Disable the Ball Catch.

Lock GroupIn the Lock Group, the back section machining can be manipulated. There are three lock set-ups to use.


About Manual Operation

About Manual OperationFrom this screen, you can control certain functions of the machine in manual mode. This screen is mainly used in troubleshooting, checking cut specifications, and maintenance.

FIGURE 2-23. Manual Operation Screen

2-43



Jog Controls

Width Adjust:• Open: Press and hold the Open button to open the width adjust carriage. To stop the carriage, release the button. The carriage will also stop if the positive travel limit eye is activated.

• Close: Press and hold the Close button to close the width adjust carriage. To stop the carriage, release the button. The carriage will also stop if the negative travel limit eye is activated.

• Clear Jog: Press to clear the current Jog command and go back to the original starting position.

Door:• Stop: Press the Stop button to extend or retract the appropriate door stop.• Clamp: Press Clamp to activate the cylinders that clamp the door.

Router:• Up: Press and hold the UP button move the Router up. Release the button to Stop Jog

• Down: Press and hold Down to move the Router down.Release the button to Stop Jog



Screw

Quick Dump Hopper: Press button to dump the screws in the active Hoppers.Clear: Press to clear screws in hopper system.Load: Press this button to start the loading pro-cess of the HoppersAir Injection: Press to inject air into the hopper system. Drive screws through tubes.Shift Drivers In /Out: The ''In'' button shifts the six shooters over hinges. The ''Out'' button shifts the six shooter out of position.

Carousel

Counter Clockwise: Press and hold to rotate the Hoppers Counter Clockwise. Release button to stop.Clear Jog: Press to clear the current Jog command and go back to the original starting position.Clockwise: Press and hold to rotate the Hoppers Clockwise. Release button to stop.

Lock

Lock Location:• Left or Right: Press and hold buttons to jog the lock location left or right. To stop, release the button

• Clear Jog: Press to clear the current Jog command and go back to the original starting position.

• Speed: Select the white box and enter the speed of the carriage. The range is 1% to 100%. Use the number pad to enter the desired speed and press OK when fin-ished.

Burn Chipout: Use this button if a new Chipout Block is installed on the lock section. Press to start the burn sequence. A new hole will be slowly drilled. the process will automatically stop when finished.

2-45



Feed

Feed (990-FX):• Reverse: Press and hold the Reverse but-ton reverse the feed of the door. To stop the feed, release the button.

• Forward: Press and hold the Forward but-ton to move the door feed forward. To stop the feed, release the button.

• Normal Speed: Press and hold the Normal Speed button to slow speed. To return to previ-ous speed, release the button.

Feed (Buffer Table):Controls the Table next to the Jamb Feed.• Feed Auto: Press and hold the Normal Speed button to slow speed. To return to previous speed, release the button.

Test Mode and Hinge Burn Chipout

Chip Out: Use this button if a new Chipout Blocks are installed on the Hinge section. Press the to start the burn sequence. a new hole will be slowly drilled. the process will automati-cally stop when finished.Command Code: Displays current command code.Test Mode: Select to toggle the Test Mode on or off.Test Mode runs the hinge cycle, but does not extend the tools. This is primarily used to verify a new template is correct and the hinge carriage will not bump into the H-Block or other assemblies.


About the Setup Screen

About the Setup ScreenSelect the Setup Button to perform a calibration of the lock location. This calibration adjusts the position of the lock carriage in the X,Y,and Z direction. Use this screen if the parameters of the rear machining is not in specification.

Enter a Positive or Negative Number

Determine when to enter a positive of negative number by using your Left Hand. Use the cut on the door as a reference. Hold out the left hand with the first finger pointed at the cut on the door, second finger and thumb at right angle to each other. The first finger represents the positive direc-tion of the ‘Z” axis, the thumb represents the positive direction of the ‘Y” axis, then second finger represents the positive the direction of the ‘X’ axis.

2-47



Entering Calibration Offsets

Below are general instructions to perform a calibration.

1. Check for deviations in the expected machining and actual machining. Measure the offset from the expected result. Use this number to enter into the offset box under the inaccurate parameter.

Note: Maximum offset is 0.50 inches. If more than 0.50 inches of adjustment is needed, there is a high probability that another issue may be causing a problem. If issues can not be resolved, contact the KVAL Service Center KVAL Inc. (1-800-553-5825). See “Getting Help from KVAL” on page 1-14.

5. Run a test door again to verify the offset correction was successful.6. Keep running a test door and adjusting the offset until satisfied with the result7. After satisfied, click the Combine with Base button to store the calibration.

Y -

Y-

X Axis Positive movement

Z Axis Positive movement

Y Axis Posi-tive movement

Z -

X -

Y +

Z +

X +

Lock Plate CutFacing the Rear Section

2. Enter the offset positive or negative number in the box next to the +/- Offset button

3. The Base display box keeps a running total of data entered to help keep track of the changes.

4. The Combine with Base button merges the offset number to the base to adjust the servo.



Calibration Steps for the Lock Location

The Lock Location Calibration uses the X axis to tune the lock location. See “Entering Calibration Offsets” on page 2-48 for information about entering data. Below is a illustration on face plate movement.

Lock Location Calibration

FIGURE 3. Reference Door Lock

Lock Location

• The Base calibration sets the distances of the LH and RH Stops from the Home Limit as a reference.

• 6’-8'' to 8’ 0”: Tunes the distance of the stops from the reference (HOME) for LH and RH doors of each door length.

Note: Door lengths may vary per option selected.

To start, run a known good lock cut at a standard location on a Right Hand or Left Hand door.

Once the lock cut is completed, check the distance from the top of the door to the center of the lock.

Note the measurement value and compare to specification

If the lock location is correct, there is no need to perform this process, If it is not correct, follow the instructions in See “Adjusting Lock Location” below.

Measure

2-49

KVAL 990-FX Operation Manua
l


Adjusting Lock Location

1. Select the size door (6'8''-7'0''-8'0'')2. Select Right Hand or Left Hand depending on the door

run through process. 3. Under Base, select the Combine with Base button.4. Enter a positive number to move the lock cut to the left.

Enter a negative number to move the lock cut to the right.

5. Re-run the lock cut.6. Measure again and repeat steps 3 to 4 until the center of

the lock is at the desired cut location.7. Once the completed with calibration, select the Combine

with Base button to store the data.8. Exit Main Calibration Screen.

Screw Shift Positions

This menu adjusts the screw drop location.Adjusts the six shooter in or out. Use if a screw is not dropping correctly and binding up at the applicator.



Timing: Front Section and Back Section

Use the Timing Controls to tune the synchronization of the Carriage Head routine and the Face Plate routine. If Either process is finishing too soon or later than each other, use the slide controls to match the timing.Note: This is rarely used. In some cases severe climate changes may cause some of the cylinders to become sluggish.

Screw Type Positions

Adjusts the hopper to bin location. If the hopper is not aligned to the pickup bin, use this control to adjust the location.

Width Positions

Adjust the width clamp settings.

2-51



Timing (Infeed and Outfeed)

• Infeed Stop: This is distance the clamped door is located after the “After-Indeed eye”.

• Out feed Stop: This is the distance the clamped door is located after the “Before-Out-feed eye.


Diagnostic Screen

Diagnostic ScreenThe Diagnostic screen displays all the tasks the 990-FX performs. This screen can help with trou-ble shooting by associating the error code to machine sections or functions. The top line will have the most current routine that is running. If the machine issue can not be resolved, call KVAL Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the KVAL representative. This will aid in troubleshooting and shorten down time.

The Diagnostic screen keeps track of the all the doors processed on the machine. The quantity is displayed in the Total Door Count box.

To keep track of daily production, the quantity of doors produced in a day is displayed in the Daily Door Count box. This count can be reset with the Reset Count button.

FIGURE 2-1. Diagnostic Screen

2-53


Diagnostic Screen

Door Count

The Door Count box keeps track of all doors processed on the machine and the daily count of doors processed. The Total door count cannot be reset. The Daily count can be reset. Use the daily count to keep track of the throughput of daily manufacturing.

Total: Number of doors pro-cessed from the Initial start up of the machine. Cannot be Reset.

Daily: Number of doors pro-cessed through-out the day. This is additive until reset.

Reset Count: Push to reset the Daily count of doors.

KVAL 990-FX Ope2-5

ration Manual4

Appendix: Machine Component Terms

Appendix: Machine Component TermsThis table includes definitions of common terms.

Machine Terminology

Machine

Electrical Panels

Electrical Panels contain the brains and power for the machine. The Main Electrical Panel contains the main PLC and servo drives. The High Fre-quency Panels contain the VFD’s to drive routers, width adjust, and feed motors.

Door Clamp The door clamp secures the door for stable routing and drilling.

Jamb Clamp The jamb clamp secures the jamb to hold it in place as routing and drilling.

Door Stop The door stop sets the door in the correct position for processing.

Jamb Stop The jamb stop sets s reference for the jamb to be in the correct position for processing. It is located on the front section of the machine and is set man-ually by the operator.

Tools

Routers Routers are located int he Carriage Heads and on the Back Section. The routers rout the hinge pockets and rout face plates. Typically Carriage Heads contain two routers that cut in the opposite directions to create a smooth cut.

Bolt Drill The bolt drill is located on the back section. Drills a bolt hole on the lock edge of the door.

Lock Bore The lock bore is located on the back section. Drills a lock hole on the face of the door.

Pre-drills The pre-drills are located in the Carriage Heads. They pre-drill screw holes for hinge screw application on the door and the jamb.

Chisels (opt) Chisels are located in the Carriage Heads and the back section. The chis-els square the corners on the hinge pockets and the lock plate.

Chip-Out Block

Chip-Out Blocks are located under some drills to reduce tear-out on the edges of the cut.

Operation

Operator’s Station

The Operator’s Station is the interface of operator and machine. It contains power controls and touch screen interface to controls the cutting parame-ters of the door.

Machine Con-trol

Located mid machine, manually set Feed (Auto-Man), LH or RH door, Start and Stop machine.

Door Clamp Pedal

The Door Clamp Pedal is a foot pedal that activates the Door Clamp to either clamp or unclamp the door.

Jamb Clamp Pedal

The Jamb Clamp Pedal is a foot pedal that activates the Jamb Clamp to either clamp or unclamp the jamb.

Six-Shooter The Six-Shooter is located at the left side of the machine.Six Shooters apply hinges and the secures them with screws. (3x3 pattern)

Eight-Shooter (Opt K)

The Eight -Shooter is located at the left side of the machine.Eight Shooters apply hinges and the secures them with screws. (4X4pattern)

2-55


Appendix: Machine Component Terms


Index
Numerics110V / 24 V terminals
location electrical panels2-24

Aauto enable/disable buttons

description2-40, 2-41

Bback section

key assemblies2-20back section group

description2-42back section status

feedback2-37base

readout description2-48

CCalibration

enter a positive of negative number?2-47calibration

lock location2-49control power indicator light description2-33control transformer switch

power up2-33, 2-35

Ddiagnostic screen

description2-53door spec group

description2-40

Eelectrical panels

description2-23emergency shutdown

description2-10, 2-35

Ffront section

key assemblies2-15front section status

feedback2-37

KVAL 990-FX Oper1

Hhigh frequency panel

description2-24home button

description user interface2-39using2-34

Iin-feed section

key assemblies2-2input and output terminals

location electrical panels2-24

Llock

calibration2-49lock access to user screens2-7lock location

adjusting location2-50lockout and tagout Guidelines1-12lockout procedure1-10

MMachine

description of machine2-2machine feed back

user output2-37machine feedback

front section status2-37general2-37servo positons2-37

machine statusgeneral feedback2-37

main electrical paneldescription2-23

main screeninterface2-38

manual operationinterface2-43

menu map2-36

Ooperator’s tour

top view2-2out-feed

ation Manual

Indkey assemblies2-22

PPLC

location in main electrical panel2-23power

lock out procedure1-10preset selection

description2-40

Rremote operation, setting up machine for1-16reset machine button

description user interface2-39Right Hand Rule2-47

Ssafety guidelines1-5Safety Sign Off Sheet

Safety Concerns1-19servo positions

feedback2-37setup screens2-47shut down system

description user interface2-39six light panel

description2-29sequence list2-29

start machine buttonpower up2-33

stop sequence buttondescription user interface2-39

Ttagout procedure1-10

Uuser interface screens

menu map2-36

Zzero-energy start-up

clean up1-12inspect1-12

KVAL 990-FX Oper2

ex

ation Manual


Customer Service

Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

Contacting KVAL

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

Email: [email protected]


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