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Kval 990-H, Operation Manual

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   Chapter 1 at a Glance

1-1

KVAL 990-H Operation Manual

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.

Chapter 1 at a Glance

Section Name

Summary

Page

Overview of the System

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

page

 

1-2

Safety First!

IMPORTANT safety information is described in this 
section

page

 

1-6

Lockout Tagout

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

page

 

1-11

Zero-Energy to Start-Up

Procedure to power up your machine for the first time.

page

 

1-13

Getting Help from KVAL

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

page

 

1-15

How to Download the 

Service Application

Procedure to download an interactive application to 
allow Service 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

Summary of Contents for 990-H

Page 1: ...Innovation Quality Honesty Operation Manual Published 10 24 18 990 H Pre Hanging Door System 990 H Operations Manual ...

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

Page 3: ...erience 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 above Thank ...

Page 4: ...KVAL 990 H Operation Manual ...

Page 5: ...e Steps Before Lockout Tagout 1 11 Lockout Tagout Power 1 11 Lockout Tagout Air Supply 1 12 Start Maintenance 1 12 Post Maintenance Steps 1 12 Zero Energy to Start Up 1 13 Getting Help from KVAL 1 15 On Line Help 1 15 Product Return Procedure 1 15 How to Download the Service Application 1 17 Download Application 1 17 Safety Sign Off Sheet 1 20 A Note to the Operator 1 20 Chapter 2 Operation of the...

Page 6: ...owering Operations for the 990 H 2 25 How to Power Up the 990 H 2 25 Home the 990 H 2 26 How to Power Down the 990 H 2 26 Safety Controls 2 27 Emergency Shutdown and Recovery 2 27 To Resume Normal Operation after an E Stop 2 27 Air Brake on 990 FX Six Shooter 2 27 Summary of the Interface 2 29 Machine Control and Calibration Screens 2 29 Machine Feed Back 2 31 Controlling Access to User Screens 2 ...

Page 7: ...Table of Contents KVAL 990 H Operation Manual About the Pre Drill Screen 2 49 Entering Pre Drill Pattern Data 2 49 Example of Data Input 2 50 Diagnostic Screen 2 51 Status of I O and E Stops Screen 2 52 ...

Page 8: ...990 H Table of Contents ...

Page 9: ... 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...

Page 10: ... 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 re...

Page 11: ...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 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 ...

Page 12: ...ed 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 hin...

Page 13: ...ut 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 1...

Page 14: ...logy 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 wa...

Page 15: ...e is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before performing any mainte nance or repairs on thi...

Page 16: ...ny repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out the electrical and air pressure systems This sh...

Page 17: ... 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 Safet...

Page 18: ...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 19: ...pring 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...

Page 20: ...ce 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 conditi...

Page 21: ... 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 compr...

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: ...Thursday 6 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...

Page 24: ...odified 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 ...

Page 25: ... 2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Google we...

Page 26: ... 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 ...

Page 27: ...How to Download the Service Application 1 19 KVAL 990 H Operation Manual Page Intentionally Left Blank ...

Page 28: ...ow 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 electrica...

Page 29: ...Safety Sign Off Sheet 1 21 KVAL 990 H Operation Manual ...

Page 30: ...nce 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...

Page 31: ...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 t...

Page 32: ...r 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 Si...

Page 33: ...ns 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 Hinge screws Lock Bore Contains Router Face Plate Drill Bolt Drill Drill x2 Drills lock hole on the face of the door Carriage Head Center Carriage H...

Page 34: ... the LCD touch screen monitor contains interfaces for the ON 2012 Feeder 990 H2 and the ON12 H Stacker Machine Controls Touch Screen LCD See Main Screen on page 2 32 Keyboard and Mouse Control Circuit Powers up the machine Powers Down the Machine Emergency Stop Stops machine in an emergency situation Start Stop Starts the Machine Pro cess or Stops the Machine Process Machine Controls Store Program...

Page 35: ...s 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 in...

Page 36: ...us 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 ...

Page 37: ...ile 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 shooters In 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 Ke...

Page 38: ...tion 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 Chisel...

Page 39: ...r 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...

Page 40: ... 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 demagnetiz...

Page 41: ... as well as both at the same time About the Six Shooter System KVAL 990 H Operation Manual 2 12 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 G...

Page 42: ... 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...

Page 43: ... 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 assembly See 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 f...

Page 44: ...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 ...

Page 45: ...plate 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 ...

Page 46: ...ore 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...

Page 47: ...eration Manual 2 18 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 ...

Page 48: ... 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 Freq...

Page 49: ...ual 2 20 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 Supplies 110 V 24 V Terminals High Voltage Section Input Output Terminals Servo Drives ...

Page 50: ...ght 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 ...

Page 51: ...n loading area of Feeder and machine process area is 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 DoubleClickthe 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 ...

Page 52: ...cessing 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 ...

Page 53: ...eads 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 Machine Start Summary KVAL 990 H Operation Manual 2 24 ...

Page 54: ...ttons 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 in...

Page 55: ...Main Screen touch screen 1 The machine will move to the home position at the in feed end of the machine 2 The machine will then move to about the middle of 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 be...

Page 56: ...y if you press the STOP button on the operator s station To Resume Normal Operation after an E Stop If an E Stop is activated use the following procedure to recover after the cause of the emergency stop is resolved 1 De activate the E Stop switch by pulling it out 2 Push the START MACHINE button on the operator s station 3 Press the Reset Light Curtain Buttons on the Feeder and Stacker Air Brake o...

Page 57: ...a 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 th...

Page 58: ... 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 ca...

Page 59: ...ing the error code to machine sections or functions See 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 KVAL 990 H Operation Manual 2 30 ...

Page 60: ...o 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 ...

Page 61: ... Operation Manual 2 32 Main Screen 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 Main Screen Descriptions FIGURE 2 4 Main Screen ...

Page 62: ...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 ...

Page 63: ...ters 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 t...

Page 64: ...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 ...

Page 65: ...en 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 ...

Page 66: ...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 h...

Page 67: ...ose 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 F...

Page 68: ...pers 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 KVAL 990 H Operation Manual ...

Page 69: ...cted 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 the offset from the expected result Use this number to enter into the offset box under the inaccurate parameter 2 Enter the offset positive or negative number in the white box below the Offset title to adjust the servos in...

Page 70: ...d 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 Eit...

Page 71: ...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 ...

Page 72: ...k 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 Enabl...

Page 73: ...cator Posi tioning Option X Offset X 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 l...

Page 74: ...libration 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 ...

Page 75: ...to 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 IN Z nega...

Page 76: ... 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 Z positive Offset plunges IN Z negative Offset retracts Out Setup Hinges 1 3 Screens 2 47 KVAL 990 H Operation Manual ...

Page 77: ...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 Z positive Offset plunges IN Z negative Offset retracts Out Setup Hinges 1 3 Screens KVAL 990 H Operation Manual 2 48 ...

Page 78: ...ill 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 E...

Page 79: ...90 H Operation Manual 2 50 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 1 2 x 3 x y FIGURE 2 7 Pre Drill Samples ...

Page 80: ...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 ...

Page 81: ... 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...

Page 82: ...s 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 Status of I O and E Stops Screen 2 53 KVAL 990 H Operation Manual ...

Page 83: ...Status of I O and E Stops Screen KVAL 990 H Operation Manual 2 54 ...

Page 84: ...iption2 51 2 52 door spec group description2 33 E electrical panels description2 19 emergency shutdown description2 27 e stop light description2 21 Exit Application2 37 F front section key assemblies2 9 front section status feedback2 31 H high frequency panel description2 19 high voltage electrical panel2 19 hinge carriage user interface description2 46 hinge heads locations terminology2 9 hinge s...

Page 85: ...3 product return procedure1 15 Q quick start machine2 25 R remote operation setting up machine for1 17 return material authorization RMA 1 15 returning the product to Kval1 15 router user interface description2 46 S safety guidelines1 6 Safety Sign Off Sheet Safety Concerns1 20 service center contacting information1 15 servo drives location in main electrical panel2 19 servo positions feedback2 31...

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Page 88: ...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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