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Safety Sign-Off Sheet

1-16

KVAL 990-HB Operation / Service Manual

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 Service Department at (800) 553-
5825 or email at [email protected].

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Summary of Contents for 990-HB

Page 1: ...Innovation Quality Honesty Operation and Service Manual Published 2 23 15 990 HB Pre Hanging Door System ...

Page 2: ...dows 7 is a registered trademark of Microsoft Corporation All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated Contacting KVAL Customer Service For further information about this manual or other Kval Incorpo rated products contact the Custo...

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 HB Operation Manual ...

Page 5: ...o Start Up to Operating State 1 11 Getting Help from KVAL 1 13 On Line Help 1 13 Product Return Procedure 1 13 Safety Sign Off Sheet 1 16 A Note to the Operator 1 16 Chapter 2 Operation of the 990 HB Operator s Tour 2 2 About the 990 HB 2 3 In Feed Section 2 3 Hinge Carriage 2 4 Six Shooter System 2 5 About the Six Shooter Assembly 2 8 Driver Assembly 2 8 About the Electrical Panels 2 13 Descripti...

Page 6: ...Chapter 3 Calibration of 990 HB About Calibration 3 2 Before you Calibrate 3 2 Flow Chart of Calibration 3 3 About the KVAL Calibration Routine 3 4 Calibration Slot Drilling Specifications 3 5 Run the Calibration Routine 3 6 Select Calibration 3 6 Select Door Parameters 3 6 Load the Door and Start the Cut 3 6 Check Specifications of the Front Section 3 7 General Instructions to Adjust Parameters 3...

Page 7: ...e Lubricator 5 6 Priming the Air Line Lubricator 5 6 Lubrication Points on the 990 HB 5 7 Feed System 5 7 Screw Driver 5 8 Back Section 5 9 Replacing Bits 5 11 Replacing Bits in the Front Section 5 11 How to Access to Bit Assemblies 5 12 Remove and Replace the Screwdriver Bits 5 14 Mechanical set up of the 990 HB 5 16 Front Section 5 16 Back Section 5 17 Chapter 6 Troubleshooting the 990 HB About ...

Page 8: ...justing Cylinder Extension Speed 6 13 Adjusting Cylinder Retraction Speed 6 13 Network System Overview 6 14 Connections to Servo Drives 6 15 High Frequency Panel Node Connections 6 16 Frame Screw Driver and Back Section Node Locations 6 17 Frame Node Connections 6 17 Screw Driver Nodes 1 3 6 17 Back Section Node 6 18 ...

Page 9: ...iew of the 990 HB Door Hanging System 1 2 About this Manual 1 2 Safety First 1 3 Safety Sheet Sign Off Sheet 1 3 Safety Terminology of Labels 1 3 Safety Guidelines 1 3 Lockout Tagout Procedure 1 7 Follow the P R O P E R lockout rule of thumb 1 9 Zero Energy to Start Up 1 10 Zero Energy State to Start Up to Operating State 1 10 Getting Help from Kval 1 12 On Line Help 1 12 Product Return Procedure ...

Page 10: ... with X Y Z servo motors In total there are nine axes for the hinge routers chisels predrill three additional axes for the face plate router chisels and a final axis for lock positioning In addition an AC servo motor is used to drive the feed belts to accurately position the door without belt scuffing After the automatic routing and boring cycle three hinges are simultaneously fastened with three ...

Page 11: ... and service and maintenance information It includes identification of machine assemblies power up and power down steps and informa tion about using the user interface The Troubleshooting and Maintenance sections are directed toward qualified service technicians TABLE 1 1 Title Part Number 990 HB Operation and Service Manual 211_OPSRVDOC_990HB ...

Page 12: ...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 means if the danger is not avoided it will cause death or serious injury WARNING means if ...

Page 13: ... 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 ma...

Page 14: ...pply 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 power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or l...

Page 15: ...hine 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 Pr...

Page 16: ...ts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shut down 3 Obtain locks keys and tags from your employer s lockout center 4 Disconnect power a Turn the disconnect switches on the main electrical panel to the OFF position Then pull out the red tab and place a padlock through the hole Place your tag on the padlock as per the tagout guidelines below see illustr...

Page 17: ...ety devices are installed 8 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 9 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 10 The tags must be destroyed and the locks and keys returned to the lockout center L...

Page 18: ... device such as the one shown here Follow the P R O P E R lockout rule of thumb P Process shutdown R Recognize energy type electrical pneumatic mechanical etc O OFF Shut off all power sources and isolating devices P Place lock and tag E ENERGY Release stored energy to a zero energy state R Recheck controls and test to ensure they are in the OFF state ...

Page 19: ...lease 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 ...

Page 20: ...ut 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 ...

Page 21: ...m 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 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 See Chapter 3 System IT Administration on page 3 1 for more information Product ...

Page 22: ...ower 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 doc...

Page 23: ...Getting Help from KVAL 1 15 KVAL 990 HB Operation Service Manual Page Intentionally Left Blank ...

Page 24: ... 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 elec...

Page 25: ...Safety Sign Off Sheet 1 17 KVAL 990 HB Operation Service Manual ...

Page 26: ...Safety Sign Off Sheet 1 18 KVAL 990 HB Operation Service Manual ...

Page 27: ... of the Six Light Panel 2 14 About Sensors 2 15 About Motion of Servo Motors X Y Z and W 2 16 Quick Start 2 17 Powering Operations for the 990 HB 2 19 How to Power Up the 990 HB 2 19 Home the 990 HB 2 20 How to Power Down the 990 HB 2 20 Emergency Shutdown and Recovery 2 21 To Resume Normal Operation after an E Stop 2 21 Safety Hooks 2 21 Description of User Interface Screens 2 22 Screen Selection...

Page 28: ...nd face plate is drilled Figure 2 1 below shows locations of some key assemblies on the 990 HB Valve Bank 2 Lock Bore Assembly Electrical Panel 2 Valve Bank 3 Electrical Panel 1 Out Feed Valve Bank 1 Operator s Station Six Shooter 1 Hopper B3 Hopper A1 Hopper B2 Air Tank Front Section Back Section Left Head Six Shooter 3 Right Head Six Shooter 2 Center Head In Feed Path of Hinge Screw through tube...

Page 29: ...mbly Apply up to three hinges Six Shooter Attach the hinges with screws Six Shooter Cut a lock and lock plate Back Section In Feed Section Door is input from previous machine Includes automatic door width adjustment Door is feed through machine for processing The door is automatically positioned while the operator loads and clamps the hinge jamb Lock Back Section Operator Controls Feed System Hydr...

Page 30: ... by the six shooter Left and Right chisels 2 per to create a square cut Pre Drill Drills pilot holes for insertion of screws on the jamb and the door Counter Rotate Router Routs the hinge pocket on the jamb and the door Creates a clean cut with no chipping Left Chisel Chips upper left and lower left corners to a square cut Router Routs the hinge pocket on the jamb and the door at the same time as ...

Page 31: ... colored screws or switch over to reload There are 2 Hoppers per Six Shooter Three Six Shooters that deliver the hinge to the hinge pockets and then attaches them with six screws on the jamb and the door The Dual Hopper Bank The dual hoppers deliver the screws to the six shooters indicated below Select either the A or B series at the user station under the Main Screen Hopper B3 Hopper B2 Hopper B1...

Page 32: ...nder Screw Pick Off Slide Assembly Screw Pick Off Cylinder FIGURE 2 5 Hopper Part Call Outs 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 put Magnetiz...

Page 33: ...tors to speed the delivery to the Screw Receiver Tubes Quick Change Process Some Six Shooter Systems have an a quick change option to quickly change to differ ent colored screws To start the quick change process 1 Park the Six Shooter 2 Press the Load Unload button on the Six Shooter panel The back section of the Hopper will cycle upward once to shift all the screws from the back door to clear scr...

Page 34: ...Horizontal Rails Allows the Six Shooter to the move to the side for Maintenance and Manual application of Hinges Vertical Rails Tubes Delivers Screws to Hinge Applicator by way of plas tic tubes Driver Assembly Hinge Application See Driver Assembly on page 2 8 Vertical Cylinder Drives Six Shooter Up and Down Spring Tension for vertical movement FIGURE 2 6 Six Shooter Call Outs Driver Assembly The ...

Page 35: ...atch Arm Cylinder Moves latch arm in and out of position Air Motor Gearbox Geared to drive 6 screws simultane ously Chucks X6 Holds 6 screws aligned to the Door and the Jamb Hinge Applicator Location to attach Hinge Turret to Adjust Depth Adjustable stops to set the depth of the screw drivers Used with the Forward Limit Switch Forward Stop Limit Switch Reverse Stop Limit on other side Plunge Cylin...

Page 36: ...bolt Left Lock Plate Chisel Squares Edges of Lock Plate Right Lock Plate Chisel Squares Edges of Lock Plate Left Lock Plate Chisel Y Axis Servo Motor X Axis Servo Motor not Shown Back Section Valve Bank Lock Bore Limit Switches Bolt Drill Motor Z Axis Servo Motor Function Drill Motor Drills Pilot holes for securing lock FIGURE 2 8 Key Assemblies on the Back Section Back View ...

Page 37: ...ares Edges of Lock Plate Left Lock Plate Chisel Squares Edges of Lock Plate Lock Plate Router Motor Dust Collector Path Back Sec tion Chip Outs Lock Bore Router Motor Bolt Drill Motor Function Drill Motor Drills Pilot holes for securing lock Function Drill FIGURE 2 9 Key Assemblies on the Back Section Front View ...

Page 38: ...0 HB Operation Service Manual Out Feed The door is automatically positioned to be fed into the next machine Dust Collection Blow Off Nozzles Valve Bank Bore Motor Air Input System FIGURE 2 10 Key Assemblies on the Out Feed Section ...

Page 39: ...nel 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 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 pro tocol as described in Chapter 1 Main Electrical Panel High Frequency P...

Page 40: ...minates 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 ...

Page 41: ...ye 0VDC is sent to the PLC As a result any of the photo detectors output equals 0VDC when a door is sensed The Proximity Sensor detects metallic objects without touching them An inductive proximity sensor consists of a coil and ferrite core arrangement an oscillator and detector circuit and a solid state output The ferrite core and oscillator create a field generating out the front of the sensor W...

Page 42: ... the machine The reverse direction equates to a negative number and the forward direction equates to a positive number when entering data into the cali bration menus X Axis Y Axis W Axis Y Servo Motor Red Close Green Open Z Servo Motor Red Up Green Down Red Reverse Direction Green Forward Direction W Servo Motor Red Close Green Open width adjust X Servo Motor Red Reverse Green Forward Z Axis FIGUR...

Page 43: ...n setup through the Main Screen selections See Main Screen on page 2 24 6 Select Right Hand Door or Left Hand Door 7 Feed in a door from the Door Feeder Preset Buttons 8 Insert a Jamb pressing it firmly against the jamb stop Caution Pay Attention to the Hand Placement and Warning Stickers on the Machine While loading the jamb it is important to be mindful of the placement of your hands If hands ar...

Page 44: ... Hinges Loaded push button located on the center head 12 Press the Start Sequence push button located on the center head Caution 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 13 When the process is completed the door will feed out and a new door will feed in 14 To continue processing another door go to...

Page 45: ...rned on 2 Check to make sure all E Stop buttons are out Note A pop up is displayed on the user screen if an E Stop is pressed The pop up will indicate which E Stop has been activated 3 Make sure the electrical disconnect the electrical cabinet is turned to the ON posi tion 4 Pull out the CONTROL TRANS FORMER switch It should light up 5 Push the green START MACHINE button 6 All lights on the status...

Page 46: ...e to the home position at the in feed end of the machine 2 The machine will then move to about the middle of its travel The 990 HB is now ready for work How to Power Down the 990 HB 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 dat...

Page 47: ...e the E Stop switch by pulling it out 2 Push the START MACHINE button on the operator s station Safety Hooks Each Six Shooter head is equipped with a red safety hook These hooks are designed to catch and restrain the Six Shooter heads in the event that the air supply is shut off while the Six Shooters are at rest prevent ing the router cylinders below from being damaged However each of these three...

Page 48: ...ually run the door store door pro files and use diagnostics to help troubleshoot the 990 HB Screen Selection Menu Map Below are the menu selections for the 990 HB See About the Machine Calibration Screen on page 2 2 See About Manual Operation on page 2 35 See Diagnostic Screen on page 2 39 See About the Pre Drill Screen on page 2 32 See About the Setup Hinges 1 3 Screens on page 2 30 See Main Scre...

Page 49: ... 23 KVAL 990 HB Operation Service Manual Controlling Access to User Screens The 990 HB has the ability to lock out changes to certain parameters such a presets and calibra tions Note Locked out parameters may vary due to customer design wants To allow the operator to make changes to parameters turn the Set Up Lock to the On position When this key is in the Off position the parameters are locked ou...

Page 50: ...ce Screens 2 24 KVAL 990 HB Operation Service Manual Main Screen The Main Screen is also the startup screen for the 990 HB From this screen all the basic user interface controls are available to run a door FIGURE 2 14 Main Screen ...

Page 51: ...ming Press Home Machine after Reset Machine Stop Door Sequence Button This button stops the door in the process Shut Down System Button This button shuts down the computer Use this button as part of the shutdown pro cess See How to Power Down the 990 HB on page 2 20 Preset Selection Button Group Pressing a preset button calls one of twelve presets stored in mem ory Pressing the Modify Preset butto...

Page 52: ...p Set the parameters for the hinges in the Hinge Spec group The settings includes Hinge Enabled Disabled toggle button Router speed adjustment Adjustment is immediate Screw Enabled Disabled toggle button Hinge Calibration Enabled Disabled toggle button The choice of pre drill patterns You can select Pre Drill buttons to down load pre drill parameters or turn off this func tion To set Pre Drill par...

Page 53: ...ing 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 ...

Page 54: ...en Setup Hinge 1 3 screen Pre Drill Setup screen Lock Plate Setup screen About the Machine Calibration Screen The Main Cal button leads to the Machine Calibration screen In this screen you can perform machine calibration of the lock location and lock bore location on the back section change machine timing and speeds and position the jamb shelf on the front section FIGURE 2 15 Setup Menu ...

Page 55: ...he lock location for left hand doors only RH Moves the lock location for right hand doors only Feed System Adjustments Infeed Stop This is distance the clamped door is located after the after infeed eye Out feed Stop This is the distance the clamped door is located after the before out feed eye Jamb Shelf Height Adjustments Adjusts the jamb shelf height This parameter is usu ally set once Lock Bor...

Page 56: ...r to Figure 2 1 on page 2 for head locations Setup Hinge 1 adjusts left head Setup Hinge 2 adjusts center head Setup Hinge 3 adjusts right head FIGURE 2 16 Hinge Setup Menu 1 of 3 Hinge Carriage Adjustments Hinge Carriage Location This calibration number adjusts the position of the carriage Pre Drill Router Counter Rotate Router and Chisels in the X Y and Z direction ...

Page 57: ...adjustments are made to square the chisel cuts on the hinges 1 Upper Left Chisel X Y and Z Adjust ments here moves just the upper left chisel in the X Y and Z direction 2 Upper Right Chisel X Y and Z Adjust ments here moves just the upper right chisel in the X Y and Z direction 3 Lower Left Chisel X Y and Z Adjust ments here moves just the lower left chisel in the X Y and Z direction 4 Lower Right...

Page 58: ... time entering data and keeps precision drilling patterns The number 0 entered in both X and Y are equal to no drill See the figure below Imagine a graph over the Hinge The X and Y values in the graph are entered in the Sample Template screen shot below Note Never enter a negative number in the Y parameter The pre drill will try to drill off the door into the Delrin X Zero Point Y Zero Point Door ...

Page 59: ...s screen adjustments are made for the lock plate In the Lock Carriage menu location parameters can be adjusted for router and chisels as a unit The router and chisels may be adjusted individually as well The Lock Plate carriage is located on the back section of the 990 HB FIGURE 2 18 Lock Plate Screen ...

Page 60: ...tments in the Y and Z directions Lock Plate Router Adjustments These adjustments move routers in the X Y and Z direc tion This also adjusts the radius of the router cut Use this to compensate for minor changes in tooling during calibration Lock Plate Chisel Adjustments In this menu adjustments are made to square the chisel cuts on the lock plate See Chisel Adjustments on page 2 31 for more informa...

Page 61: ...ion Service Manual About Manual Operation From this screen you can control certain functions of the machine in manual mode This screen is mainly used in troubleshooting checking cut specifications and maintenance FIGURE 2 19 Manual Operation Screen ...

Page 62: ...o 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 but tons see Auto Enable and Disable Buttons o...

Page 63: ...ck Plate Location Operation X Axis Left or Right Press and hold buttons to jog the lock plate location left or right To stop release the button Y Axis Up or Down Press and hold buttons to jog the lock plate location up or down To stop release the button Z Axis Out or In Press and hold buttons to jog the lock plate location in or out To stop release the button Speed Select the white box and enter t...

Page 64: ... over hinges The Out button shifts the six shooter out of position Screw Drop Enable Disable Toggle button to disable the screws from being trans fered from Hopper to Six Shooter Burn Out Chip Operation Use this menu if a new Chipout Block is installed on the lock section or the hinge section Press the appropriate button to start the burn sequence a new hole will be slowly drilled the process will...

Page 65: ...can not be resolved call KVAL Inc 1 800 553 5825 Have any error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten down time The Diagnostic screen keeps track of the all the doors processed on the machine The quantity is displayed in the Total Door Count box To keep track of daily production the quantity of doors produced in a day is displayed...

Page 66: ...Diagnostic Screen 2 40 KVAL 990 HB Operation Service Manual ...

Page 67: ...ions 3 5 Run the Calibration Routine 3 6 Select Calibration 3 6 Select Door Parameters 3 6 Load the Door and Start the Cut 3 6 Check Specifications of the Front Section 3 7 General Instructions to Adjust Parameters 3 7 Step 1 Hinge Carriage Calibration 3 8 Step 2 Router Calibration 3 10 Step 3 Counter Rotate Router Calibration 3 11 Step 4 Pre Drill Calibration 3 12 Step 5 Chisel Calibration 3 13 C...

Page 68: ...bration routine Before you Calibrate Before you start calibration check for the following common issues and ask yourself these ques tions 1 Is the loaded setup correct for the current cut 2 Are the machine stops set up correctly 3 When did the problem first start during a run at start up 4 When was the last calibration 5 Is the door square straight and bevel correct 6 Ensure the door is tight agai...

Page 69: ...t Calibration 3 3 KVAL 990 HB Operation Service Manual Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the 990 HB FIGURE 3 1 Calibration Process Flowchart ...

Page 70: ...ection It routes a horizontal slot and drills a center hole at precise specifications Using these specifications as a reference you can inspect the pattern and the specifications of the slot for inaccuracies The front end assemblies that use the calibration routine are as follows 1 Hinge Carriage 2 Router 3 Counter Rotate Router 4 Chisels 5 Pre Drill Router Hinge Carriage Counter Rotate Router Pre...

Page 71: ... with the dimensions and positioning below Slot Position Center of Door Edge Center Between H Block H Block Pilot Hole Position Center of Slot Width Diameter of Drill Depth 0 750 Inside Slot Length 1 500 Diameter of Counter Rotate Router Width Diameter of Router Depth 0 100 Outside Slot Length 1 500 Diameter of Counter Rotate Router Width Diameter of Router Depth 0 050 ...

Page 72: ...ist contact KVAL service KVAL service can remotely download the program if LAN and WEB enabled FIGURE 3 3 Select Door Parameters From the Door section of the User Interface choose the following below See Main Screen on page 2 24 1 Choose Door Height Thickness 2 Choose door Length 3 Disable three of the hinges leaving one hinge enabled Load the Door and Start the Cut 1 Load the test door into the i...

Page 73: ...e box below the parameter The Base display box keeps a running total of data entered to help keep track of the changes The Combine with Base button stores data in memory and should be used at first to set a reference and at final to store data Title of assembly to adjust Parameter to adjust X Y and or Z axis Offset Select this button to add or subtract the measured number entered Base Keeps a Runn...

Page 74: ...t need to move To move to the left enter a positive number To move to the right enter a negative number 5 Locate the appropriate Menu in the Setup interface screens 6 If there is a number in the box under X Axis select the Combine with Base button to set a reference 7 Once this number is added to the base double select the box that has 0 000 A calcu lator will be displayed Enter the offset in this...

Page 75: ...r Width and the slot on both sides of the slot a and b 3 Calculate the difference between a and b and then divide by two Refer to the example located below 4 Next what way does the slot need to move To move up enter a positive number To move down enter a negative number 5 Locate the appropriate Menu in the Setup interface screens 6 If there is a number in the box under Y Axis select the Combine wi...

Page 76: ... Setup screen and select the appropriate Z menu 4 If the depth is too deep enter a negative number of the difference of the measured and the desired depth 5 If the depth is too shallow enter a positive number of the difference of the measured and the desired depth 6 Rerun tests until the correct depth is achieved Step 2 Router Calibration Once the Hinge Carriage is calibrated to the center verify ...

Page 77: ... to the actual size of the router bit If the diameter is not correct it will affect the X Y and Z parameters Enter calculations FIGURE 3 8 Router Calibration Menu 5 Repeat until cut is centered 6 Select the Combine with Base button to finish Step 3 Counter Rotate Router Calibration Verify the Counter Rotate Router The depth of the router should 0 100 deep The length of the router should 1 000 plus...

Page 78: ... positive number Z If the Counter Rotate Router Cut depth is too deep enter a negative number If cut is shallow enter a posi tive number Diameter The diameter menu allows adjustment com pensate for discrepancies to the actual size of the router bit 5 Repeat until cut is centered 6 Click Combine with Base to finish Step 4 Pre Drill Calibration Verify the Pre Drill The depth of the pre drill should ...

Page 79: ...ter Calibration Menu 5 Repeat until hole is centered 6 Select Combine with Base to finish Step 5 Chisel Calibration Once the routers are calibrated the chisels need to be checked In order to verify the chisels a door and a jamb will be required for this procedure 1 Load in a known hinge pattern and make sure the chisels are turned on Run one hinge for this calibration 2 Check that the H block is s...

Page 80: ...he Front Section 3 14 KVAL 990 HB Operation Service Manual 4 Y Axis use a caliper to measure how much the chisel cut is off compared to the hor izontal hinge cut with the router on the jamb a Take the caliper measurement and enter it into the Y axis box b If the chisel needs to move down enter it as a negative number c If the chisel needs to move up enter a positive number d Repeat until chisel po...

Page 81: ...calibrate the back section From the Main Screen select Setup Main Cal to get to the Machine Calibration screen to access Lock Location Calibration Lock Bore Location From the Main Screen select Setup Lock Plate Setup to get to the Lock Plate Setup screen to access Lock Carriage Router Lock Plate Chisels t FIGURE3 10 Path to Calibration screen Back Section ...

Page 82: ...s in See Adjusting Lock Location below Measure FIGURE 3 11 Reference Door Lock Adjusting Lock Location 1 Select the size door 6 8 7 0 8 0 or Base 2 Select Right Hand or Left Hand depending on the door run through process 3 Under Base select the Combine with Base button 4 Enter a positive number to move the lock towards the bot tom of the door left or a negative number to move the lock towards the ...

Page 83: ... the difference from the expected result from the actual results and enter them into the boxes in Lock Bore Location 2 Under Base select the Combine with Base button 3 Enter a positive number to move the lock bore towards the bottom of the door left or a negative number to move it towards the top of the door right 4 Re run the door 5 Measure again and repeat steps 3 to 4 until the center of the lo...

Page 84: ...Calibration of the Back Section 3 18 KVAL 990 HB Operation Service Manual ...

Page 85: ...er that supplies the user interface and controls the operation of the machine With the controller KVAL can remotely help troubleshoot your machine Chapter 4 at a Glance System IT Administration 4 2 About the 990 HB Computer 4 2 Connections on the PLC 4 2 Backing up the Computer 4 3 About Remote Connection to KVAL Service 4 3 ...

Page 86: ...le also contains internal main memory The computer has a removable Compact Flash card from which it boots The controller uses a Windows 7 oper ating system with TwinCAT 2 automation software to create the PLC and Motion Control method Interface modules include A smart power supply to connect to EtherCat terminals This supply contains a LCD to display system and user messages A DVI USB module to co...

Page 87: ...lar occurrence The KVAL service team would be happy to help If any questions occur contact our service team at 800 553 5825 or at www kvalinc com About Remote Connection to KVAL Service Remote access is a powerful tool to help fix issues that occur with the 990 HB machine With the remote access our KVAL service technician is able to observe your user screen in real time read and adjust programming...

Page 88: ...System IT Administration 4 4 KVAL 990 HB Operation Service Manual ...

Page 89: ... Weekly 5 2 Six Month Checkups 5 3 Lubrication Requirements 5 4 Linear Bearings Flange Bearing and Pillow Blocks 5 4 Gear Motor Lubrication Requirements 5 5 Ball Screws 5 5 Description of Air Input System 5 5 Adjusting the Air Line Lubricator 5 6 Priming the Air Line Lubricator 5 6 Lubrication Points on the 990 HB 5 7 Feed System 5 7 Screw Driver 5 8 Back Section 5 9 Replacing Bits 5 11 Replacing ...

Page 90: ... approved to use KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32 Gulf Harmony 32 Gear Box 2000 Hours of Machine Operation or six months of operation AGMA 8 gear lube MOBILUBE HD 80 W 90 or equivalent Daily Blow off dust from the entire machine Wipe down the outside of the machine with a clean dry cloth Check tooling for wear Wipe off the photo ...

Page 91: ...L part SYS LUBEG Six Month Checkups Wash filter and lubricator bowls with soapy water Grease all bearings and tighten all bolts Access to some grease fittings is difficult and will require a special needle point grease tip supplied with your system Clean and lubricate all slides and cylinder rods with dry silicone spray Tighten all bolts Backup computer software See Backing up the Computer on page...

Page 92: ...systems on the machine Linear Bearings Flange Bearing and Pillow Blocks If the bearing is equipped with a grease fitting Zerk Fitting it should receive 1 Gram one pump from grease gun of Dura Lith Grease KVAL P N Lube EP 2 every 250 hours of operation Note Bearings without grease fittings have been pre lubricated at the factory and do not require further lubrication Zerk Fittings Zerk Fitting Loca...

Page 93: ...Ball Nut Ball Screw End Bearing End Bearing FIGURE 5 14 Example of a Typical Ball Screw Important Make sure to clean excess grease to avoid contact with feed belts clamping areas or the door Description of Air Input System The air input system takes in shop air and supplies clean dry air CDA and lubricated air to the machine The clean dry air is diverted to blow off nozzles The lubricator located ...

Page 94: ...is a good practice to check your machine lubricator to insure that it is putting the proper dose of oil in the air lines Usually 1 drop of oil every other cycle is a good rule of thumb The approved list of oil for lubricators is as fol lows KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32 Gulf Harmony 32 To prime the lubricator find an air line ...

Page 95: ...90 HB 5 7 KVAL 990 HB Operation Service Manual Lubrication Points on the 990 HB Feed System Use Lube EP2 or similar to Lubricate Chains Lubricate feed sys tem hex shaft with Silicon Spray FIGURE5 16 Feed System Lubrication Points ...

Page 96: ...Lubrication Points on the 990 HB 5 8 KVAL 990 HB Operation Service Manual Screw Driver FIGURE5 17 Screw Drive Lubrication Points ...

Page 97: ...Lubrication Points on the 990 HB 5 9 KVAL 990 HB Operation Service Manual Back Section Back View Front View Back View 2 Bottom View FIGURE5 18 ...

Page 98: ...Lubrication Points on the 990 HB 5 10 KVAL 990 HB Operation Service Manual Heads 1 1 Assemblies shown transparent Bottom Top Back FIGURE5 19 ...

Page 99: ... damage to equipment and or serious injury to personnel Caution Replacing Bits in the Front Section This section describes the steps to change the pre drill bits router bits and chisels in the heads on the front section shows the locations of the replaceable parts inside the heads Drill Bit Chisels Upper and Lower Right Router Bit Chisels Upper and Lower Left Counter Rotate Router Bit FIGURE5 20 L...

Page 100: ...ver to access the bit assemblies Remove and Replace the Router or Pre Drill Bits After lockout tagout and access has been obtained to the assemblies follow these instructions to remove and replace the router bit or the pre drill bit 1 Use a 17 mm shaft wrench and a 3 8 collet wrench to remove the bit on the pre drill or router assemblies See 3 8 Collet Wrench 17 mm Shaft Wrench FIGURE5 21 Removing...

Page 101: ... the bit depth Set the router bit to 1 3 4 and the drill bit to 2 0 from the base of the collet nut to the tip of the bit If available use the Router Bit Depth Gauge PN 432 C to set the depth of the drill Note Make sure the arbor is not bottomed out in the back of the motor If it is the arbor will not tighten and will damage the collet or other machine parts Drill Depth Set to 2 0 Router Depth Set...

Page 102: ...The bracket has a tight tolerance and is a tight fit You may have to use channel grips to remove the bracket 4 Slide out Chisel Remove Bolts with a 7 16 wrench Bracket Orientation of Chisel Slide the old chisel out of the assembly Note the orientation of the chisel FIGURE5 24 Replacing the Chisels 5 Slide in the new chisels 6 Tighten bolts back and forth until the bracket is tight 7 Inspect and ve...

Page 103: ...e machine 5 Move the Six Shooter assembly away from the machine it will move about 1 inch This provides room for hands to access the screwdriver bit holders 6 To remove screwdriver bit push the bit holder see images back toward the Six Shooter assembly and hold pull bit out of holder Slide Back Bit Holder 7 To insert screwdriver bit push bit holder back toward Six Shooter assembly and hold while i...

Page 104: ...t up procedure check positioning of each of the assemblies before adjusting In most cases they will already be positioned to your specifications by our technicians during manufacturing Positioning H Blocks The first station is precision located and is the reference point for all set up proce dures A door does not need to be in the machine for initial setup The goal of the set up is to distance bet...

Page 105: ... hinge pocket If the pocket is less than 7 inches move the stop away from the hinge router If the pocket is more than 7 inches move the stop towards the hinge router 3 Loosen the door stop fastening bolts Slide foreword or backward until the inboard edge of the door stop is positioned 1 inch less than your specified dimension from step 1 4 Tighten door stop fastening bolts 5 Load a door clamp it a...

Page 106: ...n when placed in position and that all four bolts are tightly fas tened It should be hanging lower than the surrounding metal plates It is critical that the chip out is tight and flush with the tow brackets otherwise the chip out can vibrate loose 1 Load the door into the machine 2 Clamp the door in place using the Door Clamp foot pedal Be careful to avoid the pinch points such as between the hing...

Page 107: ...ill bit has a 4 inch long fluted section A 6 inch bit is necessary for backsets and over bored deadbolts Be certain the machine is locked out electrically and the air service is disconnected Finally wait until the bit has come to full stop before getting out the collet wrenches NOTE Be certain that the face plate router depth is correct and that the router chord is fastened to the router as shown ...

Page 108: ...al set up of the 990 HB 5 20 KVAL 990 HB Operation Service Manual tions on shimming the self centering clamp system The turret bolts should never be adjusted since these were micrometer set at the factory Note ...

Page 109: ...cking on the Variable Frequency Drives 6 7 Troubleshooting with the Status Light Panel 6 7 Troubleshooting the Air Cylinders 6 12 Adjusting Cylinder Extension Speed 6 13 Adjusting Cylinder Retraction Speed 6 13 Network System Overview 6 14 Connections to Servo Drives 6 15 High Frequency Panel Node Connections 6 16 Frame Screw Driver and Back Section Node Locations 6 17 Frame Node Connections 6 17 ...

Page 110: ...tallic objects without touching them An inductive proximity sensor consists of a coil and ferrite core arrangement an oscillator and detector circuit and a solid state output The ferrite core and oscillator create a field generating out the front of the sensor When a metal object enters the field a loss in amplitude occurs The detector circuit recognizes the loss of ampli tude and generates 0VDC t...

Page 111: ...oor Outside Narrow Door Inside Door Sense Eye Before In Feed Stop Screw Drive Head Out 1 Door In Machine After Out Feed Stop Eye After In Feed Stop Screw Drive Head Out 2 Screw Drive Head In 2 Screw Drive Head In 3 Screw Drive Head In 1 Screw Drive Head Out 3 Width Adjust ment Sensors Valve Bank 1 Q Designators Width Adjust ment Sensors Valve Bank 2 Q Designators Valve Bank 3 Q Designators Before ...

Page 112: ...s in positive and negative vertical movement and also sets the home position The Z Axis sensors sets the maximum limits in positive and negative depth move ment and also sets the home position Hinge 1 Hinge 2 Hinge 3 Y Axis Home Eye Y Axis Forward Crash Eye Y Axis Reverse Crash Eye Z Axis Home Eye Z Axis Forward Crash Eye Z Axis Reverse Crash Eye FIGURE 6 27 Figure 6 27 Section View of 990 HB Y Ax...

Page 113: ... the X Axis sensors The X Axis sensors sets the max imum limits in positive and negative positions and also sets the home position The sensors are located underneath the Heads Hinge 1 Hinge 2 Hinge 3 X Axis Home Eye X Axis Forward Crash Eye X Axis Reverse Crash Eye FIGURE 6 28 Bottom View of 990 HB location of X Axis Sensors ...

Page 114: ...achines have signals on the computer that light up when the input or out put functions are energized respectively Computer controlled as well as non computer controlled machines have white 120V control power terminal strips This will indicate power supply from the respective circuits PLC controllers also have lights on them for the input and output functions You can easily find out which circuits ...

Page 115: ...ation Note Most electrical problems are related to mechanical malfunction e g stuck motors jammed chain blocked photo sensors etc Note If a solenoid valve is suspected and not cleared in the air checks section see it can be electrically jumped to check operation Error Checking on the Variable Frequency Drives VFDs Variable Frequency Drives interact with hinge and faceplate routers width adjust mot...

Page 116: ...elow to isolate the cause NOTE Be sure to proceed down the table starting with the CONTROL POWER light STEP 1 Control Power Amber If light is OFF go to item A on page 6 9 STEP 2 Overload Relay Amber If light is OFF go to item B on page 6 10 STEP 3 E Stop Amber If light is OFF go to item C on page 6 10 STEP 4 Stop Amber If light is OFF go to item D on page 6 10 STEP 5 Start Amber If light is OFF go...

Page 117: ... there is power at the Control Transformer check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip 2 Is the Disconnect Switch on the main electrical cabinet set to ON Switch 3 Is there 208 220 440 or 575 VAC to the top side input of the Control Trans former If not check the fuses at the Fuse Block and the contacts on the Control Transformer but...

Page 118: ...see the if any E Stop buttons are pulled out NOTE Location and quantity of E Stop buttons varies depending on customer need Typical locations for E Stop buttons are near the Rear Access Gate and near the Tool Changer Access Gate Stop Light OFF Check for 110 VAC between 2 and 4 If there is voltage press the Start button If no voltage check the Stop button to make sure it is all the way out and not ...

Page 119: ...VAC If no 110 VAC check the fuse If there is 110 VAC and no 24VDC replace the 24VDC Power Supply If there is 24VDC Reconnect the output wires to the 24VDC power supply Trace the output wire to the DC terminal block Disconnect all 24V positive wires from the DC from the DC terminal block except the output wire from the 24VDC power supply Check for 24VDC at between any DC and DC terminal on the DC T...

Page 120: ... on the retract port this regulates the air flow exhausting from the cyl inder and the opposite is true for the retract motion 1 Check the air pressure to the machine 2 Check the flow controls to see that they are adjusted correctly and to the proper specifications 3 Check for any obstructions to the cylinders such as screws or a misplaced tool etc FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THI...

Page 121: ...e of the cylinder which means the air is exhaust ing through the solenoid valve It maybe is necessary to purchase a rebuild kit or a new cylinder c If the valve is not receiving an electrical signal for instructions It might be necessary to call in a specialist or check with KVAL customer service at 1 800 553 5825 5 If an Air Leak is coming from an exhaust port on the solenoid air bank a Check the...

Page 122: ...ical noise and resistance to vibration and impact Figure 6 29 below shows the PLC connections in the 990 H The PLC is located in the Main Electrical Panel From the PLC connections are made to coupler interfaces located near the sec tions they control See your machine s schematic package for detailed wiring information To aid in troubleshooting the next section shows the locations of the assemblies...

Page 123: ...s Servo Drive 5 Head 3 Z axis and Back Section X axis servo motors Servo Drive 6 Back Section Y axis and Z axis servo motors Servo Drive 7 Back Section Location and Feed Motor For detailed wiring information see your machine s electrical drawings 24 VDC Input Ether CAT Output Ether CAT Input From PLC High Voltage Input Servo Drive 1 2 High Voltage Outputs Servo Drive 2 2 High Voltage Outputs Servo...

Page 124: ...s and outputs for the following VFD s The front section routers counter rotate routers and pre drills The back section lock bore and bolt drill Hinge P2P Door width outputs to the stacker For detailed wiring information see your machine s electrical drawings Coupler PLC Interface 4 7 2 1 6 5 8 3 Inputs Outputs Ether CAT Output To E Stop Circuitry Ether CAT Input From Frame Node FIGURE 6 31 High Fr...

Page 125: ...ummary this node includes the following Frame related inputs and outputs Head limits Jamb controls Foot control Control of door through machine For detailed wiring information see your machine s electrical drawings Screw Driver Nodes 1 3 The Screw Driver Nodes are located on the back of each of the three Six Shooter assembies In summary these nodes include the following Six shooter inputs and outp...

Page 126: ...de The Back Section Node is located on the back section of the machine In summary this node includes the following back section related inputs and outputs including back section servos lock plate bore door widths For detailed wiring information see your machine s electrical drawings ...

Page 127: ...ription3 7 Beckhoff CPU module4 2 bit assemblies how to access5 12 bits replacing5 11 C calibration chisel3 13 description3 2 drill3 5 flowchart3 3 front section assemblies3 4 lock location3 16 path to hinge setup3 7 pre drill3 12 router slot dimensions3 5 router steps to3 10 slot dimensions3 5 steps before3 2 strike plate3 17 suggested order of steps3 7 chisel calibration3 13 user interface descr...

Page 128: ...cription2 30 hinge spec group description2 26 home button description user interface2 25 using2 20 I inductive proximity sensor2 15 in feed section key assemblies2 2 input and output terminals location electrical panels2 13 internet access location of connection4 2 remote connection4 2 RJ45 to intranet4 2 intranet RJ45 connection4 2 J jamb insert into machine2 17 L LCD display smart power supply4 ...

Page 129: ... main electrical panel2 13 power disconnect switches1 8 lock out procedure1 8 power up troubleshooting6 6 powering up and down machine2 19 pre drill calibration3 12 user interface description2 31 pre drill bit using tool to set depth5 13 pre drill bits replacing5 12 preset selection description2 25 product return procedure1 13 programmable logic controller PLC4 2 Q quick start 990 H2 17 R refresh ...

Page 130: ...9 status light panel description6 7 use as troubleshooting key6 7 stop light description2 14 stop sequence button description user interface2 25 strike plate calibration3 17 strike plate location adjusting3 17 T tagout procedure1 8 troubleshooting air cylinders6 12 using status lights6 8 TwinCAT 2 software automation software4 2 U USB module4 2 user interface screens menu map2 22 V voltage levels ...

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