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Presets for the 960-3

2-9

KVAL Operation/Service Manual

6.

to set the top index reference, move the bar stop against the set collar and tighten.

7.

Move to the opposite end of the machine and set move flip any stop up and out of

the away. The top stop bar is set.

Tape Measure

Flip Index Stop Up or Down

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Summary of Contents for 960-3

Page 1: ...Innovation Quality Honesty 960 3 Strike Jamb Router With Shifting Cutter Head 960 3 Operation and Service Manual Operation and Service Manual Published 12 01 2020 ...

Page 2: ... is a registered trademark of Microsoft Corporation All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated Contacting KVAL Customer Service For further information about this manual or other Kval Incorpo rated products contact the Customer Su...

Page 3: ...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 userexperience kvalinc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information abov...

Page 4: ...KVAL 960 3 Operation Service Manual ...

Page 5: ...1 10 Lockout Tagout Power 1 10 Lockout Tagout Air Supply 1 11 Start Maintenance 1 11 Post Maintenance Steps 1 11 ANCHORINGTHE MACHINE TO THE FLOOR 1 12 Standard Anchoring Instructions 1 12 Zero Energy to Start Up 1 14 Getting Help from KVAL 1 16 KVAL Return and Warranty Policy 1 17 Send the Item 1 17 Acceptance of Return 1 17 Refund Turnaround Time 1 17 Kval Errors 1 17 Customer Errors 1 18 Shippe...

Page 6: ...13 Door Hand Selector 2 13 Lock Plate Shape Selector 2 14 Lock Plate Shape Selector 2 14 Emergency Shutdown and Recovery 2 15 To Resume Normal Operation after an E Stop 2 15 About the Electrical Panel 2 16 Description of the Light Tower 2 17 Chapter 3 Maintenance of KVAL Machinery Maintenance Schedule 3 2 Daily Monthly Six Month Maintenance 3 2 Maintenance NO GOES 3 4 Lubrication Schedule 3 5 Typi...

Page 7: ...Table of Contents KVAL Edge SS Manual Initial Cut on New Chip Out Block 3 15 Appendix Router Collet Assembly Basics 3 16 Checking Collet Assembly 3 16 Appendix Collet Torque Values 3 17 ...

Page 8: ...l description and a table of available options page 1 2 Safety First IMPORTANT safety information is described in this section page 1 5 Lockout Tagout Guidelines Procedures describing Lockout Tagout page 1 9 Zero Energy to Start Up Procedure to power up your machine for the first time page 1 14 Getting Help from KVAL This section describes the method to contact the KVAL service center for help The...

Page 9: ...lates must be the same size with iden tical plunge profiles If this functionality is desired and Option H Commercial Package is purchased this version of Option D must be used Option E T Strike Routing Allows quick change from T strike routing to full lip routing with the turn of a switch Cycle slows to approximately four jambs per minute due to extended router travel path Using the KVAL 960 3 Aut...

Page 10: ...amb Index Stops Two extra jamb index stops for machining dead bolt strikes Option H Commercial Package Four additional stops for 6 8 7 0 and 8 0 jambs Stops included on base machine for 6 8 doors does not include extra stops for deadlock machining TABLE 1 2 Options Options ...

Page 11: ...rface The Troubleshooting and Maintenance sections are directed toward qualified ser vice technicians only Operation Service Manual includes the following Chapter Title Description Chapter 1 Introduction Descriptions of Machine Line and Safety Information Chapter 2 Operation Inter face Descriptions of how to power machine line and operator inter face user screens Chapter 3 Maintenance Information ...

Page 12: ...ged 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 fo...

Page 13: ...wn 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...

Page 14: ...ted at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out t...

Page 15: ...t 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 operati...

Page 16: ...and tag on each disconnect Only each operator may remove their own lock and tag Important When many people are all working on the same machine you will need a multiple lockout device such as the one shown here Follow the P R O P E R lockout rule of thumb P Process shutdown R Recognize energy type electrical pneumatic mechanical etc O OFF Shut off all power sources and isolating devices P Place loc...

Page 17: ... 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 i...

Page 18: ...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...

Page 19: ...out holes with an air compressor to ensure that the anchor heads get a firm bite on the walls of the holes Insert anchors through the mounting holes in the foot pads and into the holes you have drilled into the concrete If an anchor s expansion sleeve binds inside the hole simply tap the bolt head with a hammer until the binding stops Tighten bolts until they are snug Avoid over tightening the bol...

Page 20: ...FLOOR 1 13 KVAL Operation Service Manual Insert 1 2 hardened threaded rod into the bottom of the hole using a slow twist ing motion This insures the epoxy fills voids and crevices Hardening begins in 7 minutes at room temperature ...

Page 21: ...y 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 comp...

Page 22: ... 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 ...

Page 23: ...ecord 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 service KVALinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday ...

Page 24: ... RMA _______________ Send the Item Return the item to this address Kval Inc RMA ______ Kval Parts 825 Petaluma Blvd South Petaluma CA 94952 USA Acceptance of Return We can only accept items for a return if they are still in their original packaging and in undam aged resalable condition Returns are accepted within 45 days of purchase and with an RMA number issued by Kval Inc Returns after 45 days o...

Page 25: ...o more than one 1 year after delivery will the product be covered under Warranty The repair replacement or payment in the manner described above shall be the exclusive remedy of Buyer for breach of Kval s warranty or for claims based upon failure of or defect in the products regardless of when the failure or defect arises and whether a claim however described is based upon contract warranty indemn...

Page 26: ...KVAL Return and Warranty Policy 1 19 KVAL Operation Service Manual Page Intentionally Left Blank ...

Page 27: ...low 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 electric...

Page 28: ...Safety Sign Off Sheet 1 21 KVAL Operation Service Manual ...

Page 29: ... Chapter 2 at a Glance Section Name Summary Page About the Machine General information about the machine page 2 2 Preset the Machine Links to presets before cutting the jamb page 2 3 Process a Jamb After presets process jambs page 2 4 Power Up Down How to power up and power down the machine page 2 5 Preset Descriptions Descriptions of presets page 2 6 Tour the Machine Descriptions of assemblies on...

Page 30: ... and then moves in to route for the deeper latch hole Both flat jambs with stop as well as split jambs can be accommodated Jambs are placed against either a right hand or left hand indexing stop and are clamped firmly into position at the touch of a foot pedal Standard set up is for full lip routing standard Face Plate Types A Closed Strike is sometimes used for deadbolts It eliminates the tongue ...

Page 31: ...he following presets are set Set the Door Thickness See Set the Thickness on page 2 6 Set Backset See Set the Backset on page 2 6 Set Strike Width Factory set for this model Set Depth of Strike See Set the Strike Depth on page 2 7 Set the Strike Location on the Jamb See Set the Strike Location on page 2 8 ...

Page 32: ...nd firmly into the machine stops 5 Make sure your hands are away from the Cutter Head and the clamping area then press the Start Sequence pedal 6 The machine will clamp the jamb and rout the material 7 If auto eject is set to ON the jamb will be kicked out to the catch brackets 8 If auto eject is set to Off press the Stop Sequence pedal to eject the jamb 9 The process is now complete and the machi...

Page 33: ...ach machine and main air supply is turned on 1 Turn the disconnect switch on the electrical cabinet to ON 2 Initiate the green CONTROL TRANSFORMER to the ON posi tion 3 Push the START button to start the machine Note All lights on the status light panels on the electrical box should be illuminated See Description of the Light Tower on page 2 17 1 Push the STOP button 2 Switch the green CONTROL TRA...

Page 34: ...st the backset Interior Door equates to 1 3 8 Exterior Door equates to 1 3 4 Set the Backset After setting to the desired thickness rotate the backset turrets and adjust stops If thickness is set to 1 3 8 rotate both turrets to the longer bolts If thickness is set to 1 3 4 rotate both turrets to the shorter bolts If need adjust both adjustable stops to align with the turret setting Tip Use a pract...

Page 35: ...ettings Both depths are set at the factory Strike through the Jamb Flip the top spacer away from the top plunge to allow full plunge Partial strike through the Jamb Flip the spacer under the top plunge to set a partial plunge Top Spacer Location Spacer in Partial Depth Position Spacer is Strike through the Jamb ...

Page 36: ...on of the strike Setting the Index Stops In most cases the Index Stops are preset allowing the index to be flipped up out of the way or flipped down to create a stop To set the distance of cut from top of the jamb follow these instructions 4 Loosen the set collars and bar stop 5 Slide inner most set collar in or out as necessary reading the tape from the inner most edge of the set collar Index Loc...

Page 37: ... Manual 6 to set the top index reference move the bar stop against the set collar and tighten 7 Move to the opposite end of the machine and set move flip any stop up and out of the away The top stop bar is set Tape Measure Flip Index Stop Up or Down ...

Page 38: ... face PLC to control Cutting pro cess of motor Controls and supplies volt age to machine Right Hand Index Set the top of the jamb to pre measured stop locations Air Manifold x2 Contains solenoids that drive cylinders in the machining process Left Hand Index Set top of jamb to pre measured stop locations Cutting Area Push Out Cylinder x2 Automatically pushes jamb out after machining Turret x2 Adjus...

Page 39: ...ad are identified Template Depth Adjust Adjust Strike Depth Router Bit Lock Plate Pin X2 Fixed Sets The Strike Width Shifting Air Cylinder Moves the Router Assembly into position Router Motor Bolt Plate Pin X2 Fixed Sets the Strike Width Note Width Strike Pins are mirror imaged at the Left and Right side Head Bearings X Y and Z Axises ...

Page 40: ...routers un clamping the jamb Stop Sequence This pedal stops the 960 3 s routing sequence and returns the routers to the home position and unclamps the work Control Circuit Applies power to the machine s transformer Machine Power Start Applies power to the programmable con troller Stop Removes power to the programmable controller Thickness Choose the door thickness that will be paired with the door...

Page 41: ...ence for the jamb Before starting the jamb cut choose the desired hand The Right Hand top reference is located at the left side of the machine The Left Hand top refer ence is located at the right side of the machine See Figure below FIGURE 2 1 Hand References Door Hand Selector RH or LH Lock Plate Shape Selector Off Full or Closed Bolt Plate Shape Selector Off Closed or Full Emergency Stop Door Ha...

Page 42: ...formed The Lock Plate Selector is the color white Lock Plate Shape Selector The Lock Plate is the first cut to be performed The Lock Plate Selector is the color blue Right Hand Cutter Head Start Location Left Hand Cutter Head Start Location Switch Selections Off No Cut Full Full Cut Closed Closed Cut Full Cut Closed Cut Full Cut Switch Selections Off No Cut Full Full Cut Closed Closed Cut Closed C...

Page 43: ...t 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...

Page 44: ...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 the safety protocol as described in Chapter 1 Power Supplies Input Output Ter minals 110 V 24 V Ter minals High Voltage Section Fuses and Control Transformer PLC VFD ...

Page 45: ...alize Red Machine Error Solid General Error 1 Flash EtherCat Device not Ready to Run 2 Flashes VFD Servo or Motor Error 3 Flashes 24 VDC Power Error Yellow External Error Solid General Error 1 Flash 3 Phase Voltage Error 2 Flashes Low Air Error Blue Operator Status Solid Waiting for Operator 1 Flash Reposition Door Green Machine is Operational Safety OFF Clear Safety Project not Running Red Safety...

Page 46: ...Description of the Light Tower KVAL Operation Service Manual 2 18 ...

Page 47: ...r production process Chapter 3 at a Glance Section Name Summary Page Maintenance Schedule This section describes the assemblies to schedule for maintenance Daily Weekly Six Month Checkups page 3 5 Lubrication Requirements This section describes the lubrication requirements for the machine including types of lube to use This section includes Linear Bearings Flange Bearing and Pillow Blocks Gear Mot...

Page 48: ...intenance Daily Preventive Maintenance Op Operation Description Clean Blow off dust from the entire machine Wipe down the outside of the machine with a clean dry cloth Check Check tooling for wear Clean Wipe off the photo eyes with a clean dry cloth and check to ensure that all fas tening nuts are snug Check Check the air pressure to make sure it is set at 80 psi to100 psi Clean Empty any Dust Col...

Page 49: ...bricator with an ISO 32 standard hydraulic oil KVAL part SYSLUBG Six Month Preventive Maintenance Op Operation Description Clean Wash filter and lubricator bowls with soapy water LUBE Grease all bearings and tighten all bolts Access to some grease fittings is diffi cult and will require a special needle point grease tip supplied with your sys tem Clean Clean and lubricate all slides and cylinder r...

Page 50: ... conditions are changed timing accuracy or damage may occur during the machine process Do not adjust air PSI above or below factory settings Do not adjust any and all flow controls from factory settings Do not remove shim stock Do not Change or Alter any safety assemblies E Stops Gate Locks etc Do not Change programs in PLC s or PC s Do not Alter Electrical Components ...

Page 51: ...ing Every 250 Hours of Machine Operation Dura Lith Grease KVAL P N Lube EP 2 Pillow Block Bearing Flange Block Bearing Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Note Some CNC Machines drop every 5 10 cycles Either lubricant listed below is approved to use KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 She...

Page 52: ... Zerk fitting is basically a valve that opens under pressure to allow lubricant to pass through a channel and be forced into the voids of the bearing When the pressure stops the ball returns to its closed position The ball excludes dirt and functions as a check valve to prevent grease escaping back out of the fitting The ball is almost flush with the surface of the fitting so that it can be wiped ...

Page 53: ...reliable operation FIGURE 3 3 Flange Bearings Ball Rail Bearing Ball Rail Bearings are linear bearings that are attached to positioning rails In most cases the bear ings are attached to assemblies to move them in the X Y or Z direction FIGURE 3 4 Ball Rail Bearings Greasing Flange Bearing Bearing Housings Approximatively 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 Every ...

Page 54: ...Lubrication Requirements on page 3 6 This machine is a powerful electro mechanical motion control system If servicing this machine fol low the safety guidelines Failure to do so can result in damage to equipment and or serious injury to person nel Shutdown the machine and follow the Lock Out Tag Out procedures Caution Linear Bearing Housings Z axis X4 Every 250 Hours of Machine Opera tion Linear B...

Page 55: ...livers the lubricated air to valve banks and air cylinders FIGURE 3 5 Typical Air Line Filter and Lubrication System Adjusting the Air Line Lubricator Using the knob on the top of the lubricator adjust until one drop per every other cycle is used as observed through sight glass Shop Air Input Air On Off Knob Muffler Filter purge Pressure Gauge with adjust Clean Dry Air CDA to Air Blow Off Lubricat...

Page 56: ...armony 32 To prime the lubricator find an air line on the carriage section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose Repeat this same procedure for the back section and other trouble areas It is recommended to check ...

Page 57: ...llet Assembly Basics on page 3 16 This appendix addresses Router Collect basics The 960 3 System is a powerful electro mechanical motion con trol system Follow all safety and lockout tagout procedures Fail ure to do so can result in damage to equipment and or serious injury to personnel Step 1 After locking and tagging out the machine remove the guard to allow space for motor removal a Remove the ...

Page 58: ...he 960 3 b Loosen the top bolt and left lightly tightened as a safety measure to secure motor c Be confident the motor is secure Step 3 Remove the motor from the front of the machine Be aware of motor electrical wires and the bit a Reach around and remove the loosened 3 8 hex nut from back of the plate From Step 2 b Keeping the motor secure with your hand loosen the top nut c Lift the motor up slo...

Page 59: ...ollet wrench and base wrench to loosen col let nut c Remove the bit collet nut and collect spindle Inspect collet assembly See Appendix for inspection tips Measure old bit Step 5 After inspection of collet assembly install a new bit a Install the new bit collet nut and col lect spindle Insert bit using the length measured in Step 4 b Keep motor secure and use a collet wrench and base wrench tighte...

Page 60: ... After everything is secure remove lockout tagout b Run a test door c Check the machining of the cut d If some adjustments are needed turn off air and power e Adjust the Bit Adjustment Rod to compensate for new drill bit f Repeat the adjustments until specifications of machining is satisfied ...

Page 61: ... to the forward position into the jamb the seconds person quickly butts new Chip Out Block against the jamb and tightens thumb screw The router will cut into the Chip Out Block when it returns to the starting position Note Cycle Time Is Approximately 7 Seconds Insert Chip Out Block from the back of the 960 3 to Butt up against test jamb Tighten Chip Out Block with Thumb Screws KVAL P N CHIPOUT35 K...

Page 62: ...ove and the collet won t tighten properly As with most tools parts that have metal to metal contact or are in contact with dust and pitch will wear over time or require maintenance Worn scratched dirty or out of round collets will not provide adequate holding power and can increase run out and vibration To extend the life of your collet never tighten a collet without a bit in place This can compre...

Page 63: ...lues 3 17 KVAL Operation Service Manual Appendix Collet Torque Values KVAL recommends torquing the collets Torquing adds consistency is important for repeatable machining Follow the torque tool manufacturers method of torquing ...

Page 64: ...Appendix Collet Torque Values KVAL Operation Service Manual 3 18 ...

Page 65: ...Appendix Collet Torque Values 3 19 KVAL Operation Service Manual ...

Page 66: ...cy shutdown description 15 F flange block bearing maintenance schedule 5 L linear bearing maintenance schedule 5 lockout and tagout Guidelines 14 lockout procedure 10 M maintenance daily 2 3 six month 2 weekly 2 P pillow block bearing maintenance schedule 5 power lock out procedure 10 S safety guidelines 5 Safety Sign Off Sheet Safety Concerns 20 six light panel description 17 T tagout procedure 1...

Page 67: ...Notes ...

Page 68: ...partment 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 service kvalinc com http www kvalinc com ...

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