990-H Pre-Hanging Door System · The Kval Model 990-H will rout a door and jamb for two or three...

Innovation, Quality & Honesty

Operation ManualPublished: 10/24/18

990-H Pre-Hanging Door System

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KVAL 990-H Operation Manual

Proprietary NoticeThis Manual is confidential and contains proprietary information and intellectual property of KVAL Inc., and is to be used solely by Customer as an operating manual for KVAL Inc. machines. Neither this Manual nor any of the information contained herein may be reproduced or disclosed under any circumstances without the express written permission of KVAL Inc. For authorization to copy this information, please call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call (707) 762-7367.Manual Part Number: DOC_137_3_OPThe 990-H Pre-Hanging Door System is a trademark of Kval Incorporated.Copyright 2014 Kval Incorporated. All rights reserved.

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

Windows CE® is a registered trademark of Microsoft Corporation.All other products are trademarks or registered trademarks of their respective holders, all rights reserved. Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated.Contacting 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]



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-HChapter 1 at a Glance.............................................................. 1-1 Overview of the 990-H Door Hanging System ........................ 1-2

Operation ..............................................................................................1-2Features................................................................................................1-2Options and Specials Available ............................................................1-4About this Manual .................................................................................1-5

Safety First!.............................................................................. 1-6Safety Sheet Sign-Off Sheet.................................................................1-6Safety Terminology of Labels................................................................1-6Safety Guidelines..................................................................................1-6

Lockout-Tagout Guidelines ...................................................... 1-10Follow the P-R-O-P-E-R lockout rule of thumb...................................1-10

Lockout Tagout Procedure ....................................................... 1-11Pre-Steps Before Lockout Tagout .......................................................1-11Lockout Tagout Power ........................................................................1-11Lockout Tagout Air Supply ..................................................................1-12Start Maintenance...............................................................................1-12Post Maintenance Steps.....................................................................1-12

Zero-Energy to Start-Up .......................................................... 1-13Getting Help from KVAL........................................................... 1-15

On-Line Help.......................................................................................1-15Product Return Procedure ..................................................................1-15

How to Download the Service Application ............................... 1-17Download Application .........................................................................1-17

Safety Sign-Off Sheet .............................................................. 1-20A Note to the Operator........................................................................1-20

Chapter 2 Operation of the 990-HThe 990-H Process Summary ................................................. 2-2

Machine Orientation..............................................................................2-2Typical Production Line Layout.............................................................2-2

Machine Components.............................................................. 2-3Top View of Machine................................................................ 2-4About the Operator Station and Front Section Controls .......... 2-5

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

990-H

Table of Contents

Hinges Loaded Button (Status Light)....................................................2-7About the In-Feed Section ....................................................... 2-8About the Front Section ........................................................... 2-9

About the Hinge Heads.......................................................................2-10About the Six Shooter System................................................. 2-11

About the Hopper................................................................................2-11About the Six Shooter Assembly ........................................................2-14About the Driver Assembly .................................................................2-15

About the Back Section ........................................................... 2-16Front and Rear Views of the Back Section .........................................2-17

About the Out-Feed ................................................................. 2-18About the Electrical Panels...................................................... 2-19

Electrical Panel Option: Servo Box 2..................................................2-20Description of the Six Light Panel ........................................... 2-21Machine Start Summary .......................................................... 2-22Powering Operations for the 990-H ......................................... 2-25

How to Power Up the 990-H ...............................................................2-25Home the 990-H .................................................................................2-26How to Power Down the 990-H ..........................................................2-26

Safety Controls ........................................................................ 2-27Emergency Shutdown and Recovery .................................................2-27To Resume Normal Operation after an E-Stop ...................................2-27Air Brake on 990-FX Six Shooter........................................................2-27

Summary of the Interface ........................................................ 2-29Machine Control and Calibration Screens ..........................................2-29

Machine Feed Back ................................................................. 2-31Controlling Access to User Screens ...................................................2-31

Main Screen............................................................................. 2-32Main Screen Descriptions...................................................................2-32

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

About the Entering Data into the Setup Screens ..................... 2-40How to Enter Calibration Data ............................................................2-40Enter a Positive or Negative Number? ...............................................2-41

Setup Screen ........................................................................... 2-42Main Calibration Screen Descriptions.................................................2-42

Setup Hinges 1-3 Screens....................................................... 2-45

Table of Contents


About the Pre-Drill Screen ....................................................... 2-49Entering Pre-Drill Pattern Data ...........................................................2-49Example of Data Input ........................................................................2-50

Diagnostic Screen.................................................................... 2-51Status of I/O and E-Stops Screen............................................ 2-52

990-H

Table of Contents

Chapter 1 at a Glance

1-1


CHAPTER 1 Introduction to the 990-H

This chapter provides an overview of the KVAL 990-H Door Hanging System and important safety information to follow when operating the machine.


Section Name Summary Page

Overview of the System This section provides an overview of the 990-H. It includes a general description and a table of available options

page 1-2

Safety First! IMPORTANT safety information is described in this section

page 1-6

Lockout Tagout IMPORTANT: Procedure to Lockout Tagout equipment when it is being serviced.

page 1-11

Zero-Energy to Start-Up Procedure to power up your machine for the first time. page 1-13

Getting Help from KVAL This section describes the method to contact the KVAL service center for help. The section includes how to get information from the specification plate tor provide to KVAL, service center hours, and return procedures

page 1-15

How to Download the Service Application

Procedure to download an interactive application to allow Service Technician to control your machine and help troubleshoot.

page 1-17

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

page 1-20

Overview of the 990-H Door Hanging System

KVAL 990-H Operation Manual1-2

Overview of the 990-H Door Hanging SystemThe Kval Model 990-H will rout a door and jamb for two or three hinges, drill pilot holes for the hinge screws, rout and bore for the lock and apply hinges.

Functions include hinge and faceplate routing and boring for lock and bolt. Standard features include automatic hinge routing, pre-drill, and hinge application for two or three hinge butts on both door and jamb. Machine also includes automatic door width adjustment to accommodate mixed stacks and automatic door positioning with a two-speed feed belt system.

Operation

Door is automatically positioned while the operator loads and clamps a single hinge stile (single hinge jamb), or jamb set complete with strike jamb and head jamb. Routing and boring occur while the operator places hinges into the nests of the applicators. Pressing the “IN” button fastens all hinges simultaneously.

Features

Routs two or three hinge pockets in both door and jamb, spaced so half hinges can be mounted without pins.

Pre-drills two or three hinge pockets in both door and jamb.

Applies two or three hinges to door and jamb with the hinge separated.

Number 1, 2 & 3 hinge router assemblies are movable on THK® linear ball rail to accommo-date 2040mm (80.31), 2240mm (88.188) & 2340mm (92.126)doors. The assemblies will be cylinder operated and will index with 4 position stop turrets that will be manually revolved to accommodate both door and hinge length

Hinge Routers are 1hp 3ph Hi-Frequency motors (230/380v)

Both hinge jamb stop assemblies are movable on THK® rail to accommodate 2040mm (80.31), 2240 (88.188) & 2340mm (92.126) jambs. (Cylinder operated)

Machine will accommodate nominal door thickness of 35mm (1.377) and 40mm (1.588) with some variation expected.

Machine will be equipped with one in-feed and two out-feed door stops that will register off of the top of the door. The center and right hand hinge routers and screw driver heads will be cylinder operated and will move into position to machine and apply hinges to the 2040mm, 2240 and the 2340mm door lengths

Auto positioning.

Auto width adjust.

Two independent face bore drill units to eliminate chip out. (1 top and 1 bottom 5hp drill motors) adjustable manually from 60-70mm from the door edge


1-3


Face bore; side drill and bolt plate router will be capable of shifting up to 300mm (11.811) off of center line of length of door in either direction. Total movement of 600mm. (23.622)

Face bore drills will accommodate a three stage drill bit both top and bottom for drilling differ-ent diameter holes. (Tooling to be provided by customer)50mm (1.968), 35mm(1.39) & 22mm (.866). Tooling shank will be ½"diameter).

Bolt plate router will be a 1hp 3ph Hi-Frequency motor. (230/380v)*

Bolt drill will be 3hp 3phase.

Air Blow-Off on out-feed end.

Feed direction will be left to right looking from operator's side.

Machine will be capable of routing hinge pockets in the door and jamb with doors as narrow as 520mm. Doors as narrow as 420mm can be processed with extra handling using a spacer or packer



Options and Specials Available

Option Title Description

Opt ND Narrow Doors Narrow door system adds mechanism and pro-gramming to automatically accommodate doors as narrow as 410mm in width, but without lock pro-cessing (Option includes complete secondary feed fence attached to the lock section of the 990-H that will nest under doors when not in use)

Opt P Single Point Hinge Pre-Drill Option includes three single spindle motors (one for each hinge) with programmed motion to pre-drill holes in succession for hinge screws. The screw pattern is saved and recalled by name. The cycle adds approximately 5 seconds to that of the multi-ple spindle pre-drill. (Requires Corner Squaring option.)

Out-Feed Pause Switch Adds an out-feed pause switch to the button panel attached to the center screw-driving head to tem-porarily over-ride automatic door out-feed. Allows screws to be added or replaced with a hand held screwdriver.

Programmable Hinge Loca-tions

This option upgrades the standard air cylinder shift system for hinge positions along the door edge. The cylinders and three position limit is replaced with servo motors, ball screws and software to adjust the outer hinge routers to any location within the limits of the ball rail track.

Programmable Door Index and Hinge Applicator Posi-tioning

This option compliments the programmable hinge location option by also adding four more servo motors, ball screws and software control to adjust door positioning stops and the left and right hinge application heads. This will make it possible to eas-ily create presets on the touch screen for multiple door lengths, hinge locations and lock locations – or completely custom locations can be entered for one time use. Top hinge location can vary from 198mm and screwdrivers can be aligned with cus-tom hinge locations.


1-5


About this Manual

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

The Operation Manual is directed toward operators of the machine. It includes identification of machine assemblies, power-up and power-down steps, operation and using the user interface.

The Service Manual is directed toward qualified service technician. It includes maintenance and troubleshooting information.

TABLE 1.

Title Part Number

990-H Operation Manual DOC_220_3_OP

Corner Square Feature Adds automatic corner squaring to the hinge rout-ing sequence, and fastening of square hinges. Price includes replacing x,y,z motion air cylinders on each of the hinge router head with ball screws and AC servo motor (9 total), as well as corner square chisel assemblies. The servo motor sequencing will add approximately 3-4 seconds to all hinge sequences including standard radius hinges. Adding corner squaring will add approxi-mately 6 seconds more. 10 seconds extra overall is estimated for a square hinge door unit (door and jamb). Automatic adjustment between 100mm and 89mm hinges is included with a touch screen selection, although hinge location centerlines remain the same.

Custom lock locations in Millimeters

Ability to enter custom lock location in millimeters using the touch screen for special doors. This will reference the in-feed door stop

Option Title Description

Safety First!


Safety First!

This machine is a powerful electro-mechanical motion control system. You should test your motion system for safety under all potential conditions. Failure to do so can result in dam-age to equipment and/or serious injury to personnel.

Safety Sheet Sign-Off Sheet

At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-teria to understand before operating the machine. It is highly recommended that personnel operat-ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be signed and kept for records. See “Safety Sign-Off Sheet” on page 1-20.

Safety Terminology of Labels

In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-vide safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.

There are three types of warning labels or decals:• DANGER me if the danger is not avoided, it will cause death or serious injury.

• WARNING me if the warning is not heeded, it can cause death or serious injury.

• CAUTION me if the precaution is not taken, it may cause minor or moderate injury.

Safety Guidelines

In addition to the caution and warning labels affixed to this machine, follow the guidelines below to help ensure the safety of equipment and personnel.

Ensure that all employees who operate this machine are aware of and adhere to all safety precautions posted on the machine and are trained to operate this machine in a safe manner.

Training

Never operate the machine without proper eye and ear protection.

Protective Gear

• Never reach hands beyond safety cage. Servomotors can unexpectedly move quickly.

• Never clear screws or hinges out of the machinewhile it is running.

• Never reach into the router area to retrieve ahinge. The router may still be running downafter shut down.

• Never perform any maintenance unless machineis at zero state.

• Never clean the machine while it is running.• Never walk away from the machine while it is

running.

When the Machine is ON

The compressed air system connected to this machine should have a three-way air valve for shut-off and pressure relief.

All cylinders on machine are under high pressure and can be very dangerous when activated. Before performing any mainte-nance or repairs on this machine turn off the main air disconnect. Lockout and tagout this connection.

See “Lockout Tagout Procedure” on page 1-11.

Compressed Air

Safety First!

1-7


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.

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.

Safety First!

1-9


Lockout-Tagout Guidelines


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 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

Lockout Tagout Procedure

1-11


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

1. Evaluate the equipment to fully understand all energy sources (multiple electrical supplies, air supply and pressure, spring tension, weight shifts, etc.).

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

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

Lockout Tagout Power

4. Turn off machine. See Chapter 2 for power down and power up procedures.5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF

position. Then push the red tab to pop it out. Place a padlock through the hole. Place your tag on the padlock, as per the tagout guidelines below. (see illustration below).

Power

Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided.

Insert Lock into hole.Turn Switch to the OFF position

Lock and Tag out

Lockout Tagout Procedure


Lockout Tagout Air Supply

6. Turn all air valves to the OFF position and place a pad-lock through the hole (see illustration below). NOTE: Place your tag on the padlock, as per the tagout guidelines.

Start Maintenance

7. Once the locks and tags are in place and all personnel are clear, attempt to operate the machine to ensure equipment will not operate.

8. Maintenance or repairs may started.

Post Maintenance Steps

9. After maintenance is completed, the person performing the work must ensure all tools, spare parts, test equipment, etc., are completely removed and that all guards and safety devices are installed.

10. Before removing the locks and tags, the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re-energized.

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

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

Zero-Energy to Start-Up

1-13


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 1-15.

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.

Getting Help from KVAL

1-15


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 phasevolts, electrical print number, and air print number.

Serial Number3 phase volts

Electrical PrintAir Print

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

On-Line Help

On machines with a Beckhoff® PLC and an internet connection, our service team are able to con-nect, run, and troubleshoot your machine. Ask about this procedure when calling are service team

Product Return Procedure

If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure below to return the machine or part.

Note: Non-Warranty returns are subject to a 15% restocking charge.1. Obtain the packing slip and/or invoice numbers of the defective unit, and secure a

purchase order number to cover repair costs in the event the unit is determined to beout of warranty.

2. Reason for return: Before you return the unit, have someone from your organizationwith a technical understanding of the machine and its application include answers tothe following questions:

Getting Help from KVAL


• 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?• 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). When you 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 protected from shipping damage

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


1-17


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 theSupport tab. Follow the instruc-tions on the Support web page.

3. Click the Download button todownload the application thatallows the KVAL technician tohave access to the operator sta-tion.

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

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 depart-ment.

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 a technician 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.




1-19


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.

Employee

Name (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 Ser-vice Department at (800) 553-5825 or email at [email protected].

Safety Sign-Off Sheet

1-21


2-1


CHAPTER 2 Operation of the 990-H

This chapter describes components, assemblies, and the user interface of the KVAL 990-H Door Hanging System. The content is geared to help operators understand the basic operation of the machine. Included are instructions to calibrate the machine and run a door.


Section Name Summary Page

Operator’s Tour Describes the operation machine. Machine sections and assemblies are identified.

page 2-4

Quick Start A summary of the steps to machine a door. page 2-22

Powering Operations for the 990-H

Descriptions of power up, power down, homing, and emergency stops.

page 2-25

Description of User Interface Screens

Descriptions of the user interfaces. Including Menu Maps of Operation Screens for quick look up. Descrip-tions of the buttons of each screen:

• Main Screen• Manual Operation • Calibration• Diagnostic

page 2-29

The 990-H Process Summary


The 990-H Process Summary The 990-H machines hinge pockets on both a door and a jamb and then attaches hinges to them. While the hinge process takes place a door lock and face plate is drilled. Feeding the door to the 990-H, is an ON-2012 configured as a feeder. On the output is an ON-2012 configured as astacker. Figure 2- 2 on page 2- 4, shows locations of some key assemblies on the 990-H

• Cut a hinge pocket on a door and jamb (Carriage Assembly)• Drill pilot holes for the hinge screws (Carriage Assembly)• Apply hinges.(Six Shooter)• Attach the hinges with screws (Six Shooter)• Cut a lock and lock plate (Back Section)

Note: Along with automatic control, manual control functions can be implemented. The machine also accommodates mixed stacks and automatic door positioning with a two-speed feed belt sys-tem.There is communication and timing of the door process between the 990-H feeder, and stacker.

Machine Orientation

The Front Section refers to the side of the machine with the operator’s station, and includes the three Six-Shooter heads, the front router motors, the pre-drills and chisels

The Back Section refers to side of the machine that routs the faceplate, bores the lock, and drills for the bolt.

In-Feed: The end of the machine (and its respective parts) that receives incoming doors

Out-Feed: The end of the machine (and its respective parts) that feeds out the completed door

Typical Production Line Layout

The 990-H can be paired with different feeder and stacker model numbers. This manual assumes the ON-2012 as a feeder and stacker. These machines are addressed in separate manuals.

ON-2012 Feeder ON-2012 Stacker990-H Door Hanger

FIGURE 2- 1. The 990-H Door Hanging System

Machine Components.

2-3


Machine Components.

Components DescriptionsElectrical Panels There are two electrical boxes, located near the back section

of the machineOperator’s Station The operator’s station houses the 990-H touchscreen and

other operational control switches. Note: On some options the touchscreen includes operation or other machines in the line, such as a feeder and stacker.

Door Clamp The door clamp secures the door to hold it in place as rout-ing and drilling occur.

Door Stop The door stop sets the door in the correct position during in-feed.

Jamb Stop The jamb stop acts as a jamb placement guide when jamb is being loaded

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

Jamb Clamp Pedal The jamb clamp pedal is a foot pedal that, when pressed, activates the jamb clamps to clamp the jamb in place.

Routers Routers are located in on the lower front section to rout for hinges, as well as a router on the back section to rout for the faceplate

Six-Shooters The Six-Shooters are housed in the four movable heads on the upper front section of the machine. The Six-Shooters apply the screws to secure hinges to the door and jamb

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

Bolt Drill The bolt drill is located on the back section, and drills a hole for the bolt.

Lock Bore The lock bore is located on the back section, and bores a hole for the lock

Top View of Machine


Top View of MachineThis section takes you on a tour of the 990-H Pre-Hanging Door machine

.

In-Feed from Feeder

Carriage Head-Left

Out-Feed to Stacker

Electrical Panel # 2

Front Section

Six Shooter

(x 3)

Operator’s StationOption: Located On

Extend Arm ON Machine

Six Shooter Contains:

• Hopper• Screw Deliver System• Screw Receiver• Screw Driver

Hydraulic System X3

Back Section

Air Tank

Lock Bore/ Face Plate Assembly

Control Box

Carriage Heads Contains:

• Routers (Hinge Pockets)

• Chisels (Square- Off Hinge Pockets)

• Predrills (Pre-Drill holes for Hingescrews)

Lock Bore Contains:

• Router (Face Plate)

• Drill (Bolt Drill)

• Drill(x2) (Drills lock hole onthe face of the door)

Carriage Head-Center

Carriage Head-Right

Electrical Panel # 1

Safety Scanner

Electrical Panel # 3Hinge

Loaded

FIGURE 2- 2. .Top View of 990-H Pre-Hanging Door Machine

About the Operator Station and Front Section Controls

2-5


About the Operator Station and Front Section ControlsThe Operator Station may contain the operator interfaces for one or more of the machines in the production line. For example, Figure 2- 3 below, shows an operator station with interfaces for an ON12-H Feeder and ON-2012 Stacker. In this example, the LCD touch screen monitor contains interfaces for the ON-2012 Feeder. 990-H2, and the ON12-H Stacker.

Machine Controls

Touch Screen LCDSee “Main Screen” on page 2-32.

Keyboard and Mouse

Control CircuitPowers up the machinePowers Down the Machine

Emergency StopStops machine in an emergency situation.

Start/StopStarts the Machine Pro-cess or Stops the Machine Process

Machine Controls

Store Program

To allow the operator to make changes to parameters, turn the Set Up Lock to the On posi-tion

Operator’s StationOption: Located On

Extend Arm ON Machine

FIGURE 2- 3. Operator Station



About the 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 position 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 “Powering Operations for the 990-H” on page 2-25.Door Clamp / Un-Clamp

Jamb Clamp / Un-Clamp

Foot Pedal

Control Box

Control Box

Start 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.

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 press-ing the 990-H 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.

BLANK


2-7


Hinges Loaded Button (Status Light)

The 990-FX has Light Curtain Controls at the front of the machine.

Hinge Loaded: Press after the “Start Sequence” button has been pressed and after the Six-Shooter heads have begun to move into hinge application position. This button informs the Six-Shooters that the hinges are loaded and ready to be applied

About the In-Feed Section


About the In-Feed Section• Door is input from feeder• Includes automatic door width adjustment• Door is feed through machine for processing • The door is automatically positioned while the operator loads and clamps the hinge jamb.

Hinge Head (X3): Location of Rout-ers,.Predrills, and Chisels for hinge

side of door

Hydraulic Tanks for Six Shooters: Supplies

pressurized fluid for operation of the six

shootersIn Feed: Gate Auto

Adjusts to in-fed door. Clamps and sends door through machine for pro-

cessing

Six Shooter (X3) Auto Loads Hinges and fastens Hinges to Door and Jamb

FIGURE 2- 4. Key Assemblies on the In-Feed Section

About the Front Section

2-9


About the Front Section• Includes automatic hinge routing on door and jamb • Includes pre-drill of hinge pockets• Includes hinge attachment for three hinge butts on both door and jamb• Option: Adds servo motors, ball screws and software to adjust the outer hinge rout-ers to any location within the limits of the ball rail track.

• Option: Adds four more servo motors, ball screws and software control to adjust door positioning stops and the left and right hinge application heads.

.

Six Shooter (X3): Includes Hopper, Screw Applicator, and Screw Driver. See

“About the Six Shooter System” on page 2-11

Operator Station: See “About the Operator Sta-

tion and Front Section Controls” on page 2-5

Hinge Head (X3): Loca-tion of Routers.Predrills and Chisels for hinge

side of door.

Option: Hinge Screw Applica-

tor Servo Motors (X2)

Option: Hinge Location Servo

Motor (X2)

Option: Door Index Stops(X2)

FIGURE 2- 5. Key Assemblies on the Front Section

About the Front Section


About the Hinge Heads

Pre-Drill: Drills pilot holes for insertion of screws on

the jamb and the door.

Top View

Chisels (X4): Air driven chisels square the cor-

ners of the hinge pocket on the jamb and the door. Designated as

Left and Right Chisels

Router: Routs the hinge pocket on the jamb and the door

Front View

L R

Servo Motor ‘X’ Axis Head (x3): This servo motor drives the head in highly accurate steps in the horizontal direction.

Servo Motor ‘Y’ Axis Head (x3): This servo motor drives the head in highly accurate steps in the vertical direction.

Servo Motor ‘Z’ Axis Head (x3): This servo motor drives the depth of the cut head in highly accurate steps.

See “Connections to Servo Drives” on page 6-30 . This section supplies more information about the servo drives.

Sensors:Location of Z, X, and Y home crash eyes. Each head contains them.

FIGURE 2- 6. Key Assemblies on Heads

About the Six Shooter System

2-11


About the Six Shooter SystemThere are three Six Shooters on the front section. The Six Shooters attach the hinge to the hinge pockets and then secures them with six screws on the jamb and the door.

Valve Bank: Controls air delivery to the air cylin-ders of the six shooter.

Hopper Screw Tracking Plate: Contains the screws and delivers them to the Screw Receive by way of the Screw Delivery System.

Screw Driver Assembly: Contains air motor, gear-box, screw drivers to attach all 6 screws to hinge to jamb and the door

Screw Delivery System: Six tubes that deliver the screws to the screw receiver for application to the jamb and door

About the Hopper

See the figure below for identification of Hopper assemblies. See “Hopper Process” on page 2-12 for operation descriptions.

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.

Important: Do not adjust any of the Hopper air cylinders. They are adjusted at the factory. 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.

Important: Do not mix screw types in the Hopper. Different sizes, pitches can cause uneven application of the hinge.

Screw Track-ing Plate Assembly

Gate Assembly Hopper

Hopper Cylinder

Screw Delivery Tubes Air Injected (Not Shown)

Screw Pick Off Slide Assembly

Screw Pick-Off Cylinder (Door)

Screw Pick-Off Cylinder (Jamb)

Note: The Screw Pick-Offs has the ability to deliver screws to the Jamb or Door separately or both as well as both at the same time



FIGURE 3. Hopper Part Call-Outs

Hopper Process

1. Pour the Screws into the Hopper. 2.The recommended maximum amount of screws a quantity of 600.3.The Hopper moves up and down periodically during the process by the Hopper Cylin-ders to organize the screws and deliver them to the Screw Tracking Plate.

4. The Gate Assembly monitors the quantity of screws delivered to the to the Screw Tracking Plate Assembly.

5.The screws are stacked in the slots of the Screw Tracking Plate Assembly.

6.The Screw Tracking Plate Assembly moves the Screw Tracking Plate Assembly. to capture screws six at a time.


2-13


7.Press Screw Tracking Plate Assembly.

8.On the Six Shooter Control panel to activate the Slide Assembly to drop the screws into the Screw Delivery Tubes.

9.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:1. Press the Load button on the Touch Screen.

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.

2.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.

3.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.

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

5.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.

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 plastic tubes.

Driver Assembly: Drives screw driver assemblySee “About the Driver Assembly” on page 2-15 Hinge Application:

See “About the Driver Assembly” on page 2-15

Vertical Cylinder: Drives Six Shooter Up and Down the vertical rails

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.

FIGURE 4. Six Shooter Call-Outs


2-15


About the 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.

Air Motor

Gearbox:Geared to drive 6 screws simultane-ously

Chucks X6:Holds 6 screw bits 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

Six Shooter Assembly Cylinders (x2):Moves Six shooter along rails to door and jamb.

Magnets:Four Magnets hold Hinge for Application.

Index Spacer/ Indexer:Designed for split hinges.

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

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

FIGURE 5. Six Shooter and Gear Box Call-Outs

About the Back Section


About the Back Section• Works in partnership with front section process• Includes faceplate routing and bolt boring on the edge of the door• Includes a top lock and a bottom lock drill to drill the face of the two. The two drills

eliminates chip out.

Back Section: See “Front and Rear Views of the Back Section” on page 2-17 Hydraulic

Tanks for Six Shooters

Six Shooter Crew Driver Nodes

FIGURE 2- 1. Key Assemblies on the Back Section

About the Back Section

2-17


Front and Rear Views of the Back Section

Bolt Drill Motor and drill: Machines Hole for Bolt on the side of the door

Back Section Valve Bank

Lock Bore Extend and Retract Cylinder

Face Plate Motor and Drill: Routs face plate.

Oil Reservoir

Lock Bore Limit Switch

Oil Reservoir

Edge Clamp (X2): Clamps edge of door

Self Centering ‘X’ Axis: Centers the Bolt drill in the ‘X’ axis.

Bottom Lock (Face) Bore Motor and Drill: Drills locks holes on the face of the door

Feed Belt Drive: Stationary Gate

Top Lock (Face) Bore Motor: Run the Drill to machine locks holes on the face of the door

Top Lock (Face) Bore Drill Assembly: Belt Driven to machine hole from the top of the door

Rear View

Front View

Feed Belt Drive: Stationary Gate

Servo Motor

Function Drill Cylinders

About the Out-Feed


About the Out-Feed• .The door is automatically positioned to be fed into stacker

Feed Belt Drive: Stationary Gate Feed Belt Drive: Movable Gate

Door

Main Air Input: FRL

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

About the Electrical Panels

2-19


About the Electrical PanelsThe 990-H has a Main Electrical Panel, Servo Panel, and a High Frequency Panel. Figure 2- 3 below, is an overview of the location of assemblies in the panel

Warning: 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 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 Loca-tion) in the front and back sections

The High Frequency Panel

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

.

Main Electrical Panel High Frequency Panel

PLC and Power Supplies

110 V / 24 V Terminals

High Voltage Section

Input / Output Terminals

VFD Section

PLC Interface

Servo Drives

110 V / 24 V Terminals



FIGURE 2- 3. Overview of Main Electrical Panel and High Frequency Panel

About the Electrical Panels


Electrical Panel Option: Servo Box 2

Servo Box 2 houses the servos for the Programmable Hinge Locations, Door Index, and Hinge Applicator Position

PLC and Power Supplies110 V / 24 V

Terminals



Servo Drives

Description of the Six Light Panel

2-21


Description of the Six Light Panel The six lights on this panel indicate the status of the Architect-DI system.

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

Control Power – light illuminates when the Control Transformer is pulled out and the power is working on secondary side-of transformer

Overload Relay – The overload circuit is working when light is on

E-Stop – The back gate is closed and Frame E-stop is not acti-vated when this light is on.

24VDC – light comes on once the

ACR is latch and the 24VDC power Supply is working

Stop – This light will be on if Machine Stop button is deac-tivated.

Start – This light will be on once the Machine Start button is pressed and the ACR Relay is latched.

Machine Start Summary


Machine Start SummaryThis section is a summary of the starting and running a door on the 990-H. For a full description of power up and power down of the machine,see “Powering Operations for the 990-H” on page 2-25

1. Ensure factory air is present at machine and the Feeder, the 990-H, and the Stackermain air supply valves are turned on.

2.Make sure the doors are stacked in loading area of Feeder. and machine process areais clear and ready for work.

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.

Push the green START MACHINE buttons.on all machines in the line.

Wait for the machine feedback on the operator screen dis-plays “Ready to Home”

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

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

After the machines have the Home sequence and door is fed in and auto-clamped, perform these steps

Set the Door Hand.

• RH (Right Hand Door)• Auto (Automatically receives data) • LH (Left Hand Door)

Select the desired 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.

If processing split jambs, enable the Split Jamb function.

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

2. 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.


2-23


3..Press the Start Sequence button.

4.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

5.Move out of area beyond the Light Curtain

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

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

Take Note of the Status Blink codes




2-25


Powering Operations for the 990-HThis section describe how to power up and to power down the 990-H.

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 990-H

1. Ensure factory air is applied to machine and main air supply is turned on.2.Make sure all E-Stop buttons are out. Note: The E-Stop Indicator Button on the main screen will alert the operator if an E-

Stop is activated. 3.Make sure the electrical disconnect the electrical cabinet is turned to the ON posi-tion.

Move the Feeder, 990-H, and the feeder CONTROL TRANSFORMER switches to the ON position. they all should light up.Note: Boot up may take 2 to 3 minutes.Note: Refer to the Feeder/Stacker manual for informa-

tion specific about these machines4.Push all the green START MACHINE buttons. 5.Wait for the machine feedback on the operator screen displays “Ready to Home”.

6.All lights on the status light panel on the electrical box should be illuminated. See “Description of the Six Light Panel” on page 2-21

.



Home the 990-H

After Start up the Machine Feedbacks on all machines will display “Machine Ready”. After this message is displayed the machine is ready to Home

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

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

Press the Home Machine button on the Main Screen touch screen.

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

2.The machine will then move to about the middle of it’s travel.

The 990-H is now ready for work.

How to Power Down the 990-H

1. 1

2

3

Select Shut Down System from the Main Screen to close operator interface program and shut down the operating system

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

2.Select Shut Down System from the Main Screen to closeoperator interface program.

3.KVAL also recommends that you turn the disconnectswitch on the electrical cabinet to OFF; this helps reducepossible damage resulting from power surges from electri-cal storms.

Safety Controls

2-27


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-StopIf 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

Air Brake on 990-FX Six ShooterThe 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.

Brakes are located on each side of the six shooter assemblies

Manifold

Safety Controls


Laser Safety ScannersThe safety laser scanner scans its environment with infrared laser beams.The laser scanner forms a protective field in the area of concern This protective field protects the hazardous area and enables hazardous-point protection, access protection or hazardous-area protection.

Homing

Reset the Scanner then press the Home button on the Screen.

If the Scanner field is broken the Screwdriver shift will stop and wait for you to reset the Scan-ner before it starts again.

Screw Driving Sequence

If the Scanner field is broken the Screwdriver will stop shifting and wait for you to reset the Scanner before it starts again.

Once the screw drivers start down and in if the Scanner field is broken the Machine will stop the vertical breaks will be applied and then machine will have to be reset and re-homed.

Summary of the Interface

2-29


Summary of the InterfaceThe software includes a single User Interface to control the entire machine. The interface uses side “jump buttons” to navigate the software.

Machine Control and Calibration Screens

Below are screen shots of the operator screens that control the machine.

The Main Screen is also the startup screen for the 990-H. From this screen, all the basic user inter-face controls are available to run a door. See “Main Screen” on page 2-32.

Main Control

Manual Servo Control

From the Manual Screen you can control certain functions of the machine in manual mode. From this menu branch, select to assemblies to move “jog” manually.See “Manual Operation” on page 2-36.

Setup

The Setup Screens address calibrations of the servo driven assemblies.

See “Setup Screen” on page 2-42.

See “Setup Hinges 1-3 Screens” on page 2-45.

See “About the Pre-Drill Screen” on page 2-49.

Diagnostic Screen

The Diagnostic screen displays the all the tasks the 990-H performs. This screen can help with troubleshooting by associating the error code to machinesections or functionsSee “Diagnostic Screen” on page 2-51.

Status Screen

Indicators reflect the status of the sensors in the machine. The sensors are constantly polled by the PLC during the machine operation.See “Status of I/O and E-Stops Screen” on page 2-52.

Summary of the Interface


Machine Feed Back

2-31


Machine Feed Back

At the top and at the bottom right hand corner 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

Controlling Access to User Screens

The 990-H has the ability to lock out changes to certain parameters such a presets and calibra-tions.

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

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

Set Up Lock

Main Screen


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

Main Screen Descriptions

FIGURE 2- 4. Main Screen

Machine Control Buttons

Home Machine: 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.Reset Machine: If a fault occurs that cannot be cleared, press the this button. The machine return to the start position before homing. Press Home Machine after Reset MachineStop Door Sequence: Press to stop the door in the process. Shut Down System: Press this button to shut down the computer. Use this button as part of the normal shutdown process.See “How to Power Down the 990-H” on page 2-26

Preset Selection Button Group

Pressing a preset button, calls one of twelve presets stored in memory. All the settings of the preset will populate the Main Screen entries. Pressing the Modify Preset button allows the operator to store the active Main Screen entries. After pressing the Modify Preset button:1. Select one of the buttons in which to save the parameters2.Name it to a appropriate label. 3.Select the save button to save to memory.

Door Spec Group

Set or display the parameters for the door in the Door Spec group. The settings includes:

• Current Preset: Displays the current Preset that is applied. • Length: Select the length of the door from the designated lengths from the button set.

Main Screen

2-33


Hinge Spec Group

Set or displays the parameters of the hinge settings. Hinge Enable/Disable Button: Press to enable or disable the routers that machine hinge pocket.

• Length: Displays or sets the length of the hinge pocket.

• Height: Displays or set the height (vertical) of the hinge pocket

• Depth: Displays or set depth (Z axis) of the hinge pocket

• Radius: Displays or set the rounded corners of the hinge pocket

• Speed: Select speed of the router. The range is 100% to 20%. The speed can be change during process of machining.

• Pre-Drill Pattern:.You can select Pre-Drill buttons to down load pre-drill parameters or turn off this function. To set Pre-Drill parameters, see “About the Pre-Drill Screen” on page 2-49 .

Buttons:• Jamb Kick Out: • Hinge 2 Disable/Enable:• Screw Insert Enable/ Disable

Specs

Backsection Group

Set or displays the lock parameters, in the Backsection group. The settings include lock specifications for 3 lock settings, the ability to enable and disable lock bore, bolt drill, and function drill face plate routing NS.Lock (#1-3): Dis-plays the position of the lock mea-sured from the top of the door.

• 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.• Fast Plate Routine: Select to toggle to route a face plate.

Main Screen


Auto Enable and Disable Buttons

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 processing 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 Width: Press Auto Width to toggle the auto width on or off. In auto width mode, the machine will automatically set the width adjust system for optimum clamping.

• 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.

For manual operation, see “Width Adjust Group” on page 2-38 .

Main Screen

2-35


Manual Operation


Manual OperationFrom this screen you can control certain functions of the machine in manual mode. From this menu branch, select to assemblies to move “jog” manually.

Select the Manual button to access these menus. When first pressed, the screen will open the Manual Jog screen

Manual Jog Screen

FIGURE 2- 5. Manual Screen

Exit Application

Select this button to exit out of the program and jump to the windows Desktop.

Face Plate and Narrow Door

Fast Plate Routine: Select to toggle to route a face plate.Force Narrow Door: Select and hold to manually force the clamps to accept the narrow door.

Jog Hinge Carriage 1-3 Group

In this group you can set the Speed and move direction in each of the hinge carriages in X, Y, and Z.X: left and RightY: Up and DownZ: Plunge Out and In Refer to Figure 2- 2 on page 2- 4 for head locations.Setup Hinge 1 moves left head. Setup Hinge 2 moves center head. Setup Hinge 3 moves right head.

The Speed is controlled by entering the percentage of the speed.Press and hold the Left or Right button to move the assembly. To stop release the button

Lock Location Group

Reverse: Press and hold the Reverse Button to move the position in reverse. To stop, release the button.Forward: Press and hold the Forward Button to move the position forward. To stop, release the button.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 finished.

Manual Operation

2-37


Additional Functions Group

Skip Hinge 1-3: Select to Skip the hinge router and drill functions any hinge.Jamb Knockout: 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.

Width Adjust Group

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 posi-tive 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.

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.

Feed:• Reverse: Press and hold the Reverse button reverse the feed of the door. To stop the feed, release the button.

• Forward: Press and hold the Forward button 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 previous speed, release the button.

Toggle Buttons:• The buttons to the right toggle auto functions on or off. For descriptions of these buttons, see “Auto Enable and Disable Buttons” on page 2-35 .

Manual Operation


Manual Screw Insert Group

In this group, the Hoppers can be controlled manually. • Hoppers can be toggled on or off• Can clear the screws in the hopper system • Control the air supply to the hoppers• Enable or disable screw drop • Move Heads into position

Manual Operation

2-39


About the Entering Data into the Setup Screens


About the Entering Data into the Setup Screens Select the Calibration Button to open access to the Main Cal, Setup Hinge 1-3 screen, and the Pre-Drill Setup screen. The Calibration Tab contains access to screens to adjust servo motors in the machine.These software routines are designed to fine tune the servos for optimum accuracy by entering offsets and storing the data entered.

• Main Cal: Fine tune main assemblies on the front and back section• Setup Hinge 1-3: Fine tune the Setup Hinge positions and the positions of eachassembly located in the carriages.

• Pre-Drill Setup: Set-up and store pre-drill patterns.

How to Enter Calibration Data

Adjustment menus are located in the setup screens. In these menus, you can add negative or posi-tive adjustments to move a servo to desired positions to compensate (tune) for any deviation’s from the expected cut. The calibration can then be stored.

Below are general instructions to perform a calibration.

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

2. Enter the offset positive or negative number in thewhite box below the Offset title to adjust the servosin the X, Y, and Z directions.

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

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

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 Save button to store the calibration.Note: If more than 0.50 inches of adjustment is needed, there is a high probability that

another issue may be causing a problem. Perform a visual check of the assembly to be calibrated and check the Diagnostic Screen for error reporting. Finding errors from these screens will help localize problem areas.

About the Entering Data into the Setup Screens

2-41


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 door, second fin-ger and thumb at right angle to each other. The first finger represents the positive direction 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.

Y-X Axis Positive

movement

Z Axis Positive movement

Y Axis Positive movement

Z - X +

Y +

Z +X -

Either Front Section or Back Section Cuts

Setup Screen


Setup ScreenFrom this screen you can perform machine calibration, change machine timing and speeds. The Setup Screen screen addresses the back section (lock parameters) and front section assemblies of the 990-H.

Press the Calibration and Main Calibration buttons to access this screen. Tune the assemblies on this screen by entering and stor-ing offsets to bring into reference.

Main Calibration Screen Descriptions

FIGURE 2- 6. Setup Menu

Lock Section CalibrationsSee “How to Enter Calibration Data” on page 2-40 , for instructions to enter calibration data.

Lock Locations:

Set the lock locations for 3 standard door lengths

To calibrate, 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 cen-ter of the lock.

Note the measurement value and compare to specification.

Re run the calibration routine until correct.

Face Bore Extend Timers:

This machine is designed to bore a lock with a three stage bit.

This menu allows you to set the bore times of each stage. (Shallow, Mid and Deep)

Face Plate Timers

Vertical: The amount of time, in seconds, to give the vertical movement of the lock plate when in “Fast Plate” or “Slow Plate” mode.

Horizontal: The amount of time, in seconds, to give the horizontal movement of the lock plate when in “Fast Plate” or “Slow Plate” mode.

Single Step Disable/Enable Button: Disable the Single Step button to use the three stages. Enable the Single Step button to by pass the three stages and perform the bore with one sin-gle cut.

Lock Loca-tion Measure-ments

Note: Before adjusting the Slow Lock Plate Timing, make sure the Fast Plate Routine is set properly adjusted.

Setup Screen

2-43


Screw Shift

See “How to Enter Calibration Data” on page 2-40 , for instructions to enter calibration data. Tunes the servo motor for the screw locations of Head #1 and Head #3. This is calibration is included with the “Pro-grammable Door Index and Hinge Applicator Posi-tioning' Option.

X: + OffsetX: - Offset

Feed System Timing

Infeed Stop: This is the time, in seconds, between the period the door covers the “After-Infeed Eye” and when the door clamps. Longer times will allow the door to feed longer. Out feed Stop: This is the time, in seconds, between the period the door covers the “before-out feed eye” and when the door clamps. Longer times will allow the door to feed longer.

Setup Screen


Setup Hinges 1-3 Screens

2-45



Press the Calibration and Hinge#1- #3 Calibration buttons to access these screens. Tune the Hinge Carriages and the assemblies located in the hinge carriages by entering and storing offsets to bring into reference.

• Setup Hinge 1 adjusts left head. • Setup Hinge 2 adjusts center head. • Setup Hinge 3 adjusts right head.

Hinge Carriage

See “How to Enter Calibration Data” on page 2-40 , for instructions to enter calibration data.Hinge Carriage Location: Adjustments move position of the carriage (Pre-Drill, Router, and Chisels). Essentially this moves the all tool sets together as a unit up, down, across and into the jamb and the door.

Router

See “How to Enter Calibration Data” on page 2-40 , for instruc-tions to enter calibration data.Router: Adjustments moved routers in the X, Y, and Z direction, as well as radius adjustments. This adjustment moves the router (pocket) only, the pre-drill and the chisels will stay in the same position.

X: + Offset

Y: + Offset

X: - Offset

Y: - Offset

Jamb

Door

Z: positive Offset plunges INZ: negative Offset retracts Out



Chisel

See “How to Enter Calibration Data” on page 2-40 , for instructions to enter calibration data.Adjust the four corners of the hinges in the X,Y and Z axis:• Upper Left Chisel: Jamb • Upper Right Chisel: Jamb• Lower Left Chisel: Door• Lower Right Chisel: Door

This adjustment moves the Chisels only, the pre-drill and the router will stay in the same position.

Jamb

Door

Upper Left

Lower Right

Lower Left

Upper Right

X: + Offset

Y: + Offset

X: - Offset

Y: - Offset



2-47


Pre-Drill

See “How to Enter Calibration Data” on page 2-40 , for instructions to enter calibration data.Pre-Drill: Adjustments tune the point-to-point drill in the X, Y, and Z direction. Each pre-drill hole moves the distance in the direction entered in the entry box.This adjustment moves the Pre-Drills only, the chisels and the router will stay in the same position.

Jamb

Door

X:+ Offset

Y: + Offset

X: - Offset

Y: - Offset




About the Pre-Drill Screen

2-49



Press the Calibration and Pre-Drill Calibration buttons to access this screen. From this screen, you can adjust and store up to five pre-drill screw patterns in memory.

Entering Pre-Drill Pattern Data

The X and Y valves are referenced off the bottom of the hinge on the door to the center of the hinge

The jamb pre-drill holes are equal to the mir-ror image of the parameters entered. This allows for less time entering data and keeps precision drilling patterns.

The number '0' entered in both X and Y are equal to no drill.

Name the Template

Enter Drill Hole Locations



Example of Data Input

'X' Zero Point

'Y' Zero Point

Important: Never enter a negative number in the 'Y' parameter. The pre-drill will try to drill off the door into the Delrin.

12

- x

3

+ x

+ y

.

FIGURE 2-7. Pre-Drill Samples

Diagnostic Screen

2-51


Diagnostic Screen

The Diagnostic screen displays the all the tasks the 990-H performs. This screen can help with trouble 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.

Status of I/O and E-Stops Screen



Indicators reflect the status of the sensors in the machine. The sensors are constantly polled by the PLC during the machine operation.

At the lower left hand of the screen are indicators displaying the status of the Safety controls in the machine.

• Green indicates the sensor is active.• Red indicates the sensor is not active.

Note: The illustrations in this section are designed to show the general location of the sensors. For detailed information correlate the machine ‘s electrical drawings to the sensor labels located on the machine.

Safety Screen

Displays real time feedback from the safety assemblies on the machine.

E-Stop: Verifies the activation and deactivation of all E-Stops

Safety System: Feedback from PLC


2-53





Index

Numerics110V / 24 V terminals

location electrical panels2-19

Aadditional functions

user interface descriptions2-37, 2-38adjustment menus

how to use2-40auto enable/disable buttons

description2-35

Bback section

key assemblies2-16back section group

description2-34back section status

feedback2-31base

readout description2-40

CCalibration

enter a positive of negative number?2-41calibration

entering data2-40chisel

user interface description2-47control power indicator light description2-21control transformer switch

power up2-25

Ddiagnostic screen

description2-51, 2-52door spec group

description2-33

Eelectrical panels

description2-19emergency shutdown

description2-27e-stop light

description2-21Exit Application2-37

Ffront section

key assemblies2-9front section status

feedback2-31

Hhigh frequency panel

description2-19high voltage

electrical panel2-19hinge carriage

user interface description2-46hinge heads

locations terminology2-9hinge spec group

description2-34home button

description user interface2-33using2-26

Iinput and output terminals

location electrical panels2-19

Jjog hinge carriage

user interface description2-37

KKVAL, getting help1-15

LLeft Hand Rule2-41lock access to user screens2-31lock and strike drill

user interface descriptions2-43lockout and tagout Guidelines1-13lockout procedure1-11

Mmachine feed back


Index

user output2-31machine feedback

front section status2-31general2-31servo positons2-31

machine statusgeneral feedback2-31

main cal screengroup locations2-42

main electrical paneldescription2-19

main screeninterface2-32

manual operationinterface2-36

manual screw insertuser interface descriptions2-39

Oout-feed

key assemblies2-18overload relay light description2-21

PPLC

location in main electrical panel2-19, 2-20power

lock out procedure1-11powering

up and down machine2-25pre-drill

user interface description2-48pre-drill pattern data

entering2-49preset selection

description2-33product return procedure1-15

Qquick start

machine2-25

Rremote operation, setting up machine for1-17return material authorization (RMA)1-15

returning the product to Kval1-15router


Ssafety guidelines1-6Safety Sign Off Sheet

Safety Concerns1-20service center, contacting information1-15servo drives

location in main electrical panel2-19servo positions

feedback2-31setup hinges

group location2-45six light panel

description2-21sequence list2-21

six shooterlocations on front section2-9

start light description2-21start machine button

power up2-22, 2-25stop light description2-21stop sequence button

description user interface2-33

Ttagout procedure1-11

VVFD

location in high frequency panel2-19

Wwidth adjust


Zzero-energy start-up

clean up1-13inspect1-13


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]


Date post:	10-Jul-2020
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990-H Pre-Hanging Door System · The Kval Model 990-H will rout a door and jamb for two or three...

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