Kval 990-HQ Operation Manual Download Page 9

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Chapter 1 at a Glance

1-1

990-HQ Operation Manual

CHAPTER 1

Introduction to the 990-HQ

This chapter provides an overview of the

KVAL 990-HQ 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-HQ. It
includes a general description and a table of available
options

page 1-2

Safety First!

IMPORTANT safety information is described in this sec-
tion

page 1-5

Lockout Tagout

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

page 1-10

Zero-Energy to Start-

Procedure to power up your machine for the first time.

page 1-12

Getting Help from

KVAL

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

page 1-14

How to Download the

Service Application

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

page 1-16

Safety Sign-Off Sheet

A record to track operators that are trained on the
machine.

page 1-19

Summary of Contents for 990-HQ

Page 1: ...Innovation Quality Honesty Operation Manual Published August 15 2019 990 HQ Pre Hanging Door System 990 HQ Operations Manual ...

Page 2: ...ows 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 Custo...

Page 3: ...perience 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 HQ Operation Manual ...

Page 5: ...upply 1 11 Start Maintenance 1 11 Post Maintenance Steps 1 11 Zero Energy to Start Up 1 12 Getting Help from KVAL 1 14 On Line Help 1 14 Product Return Procedure 1 14 How to Download the Service Application 1 16 Download Application 1 16 Safety Sign Off Sheet 1 19 A Note to the Operator 1 19 Chapter 2 Operation of the 990 HQ The 990 HQ Process Summary 2 2 Machine Orientation 2 2 Typical Production...

Page 6: ... How to Power Up the 990 HQ 2 24 Home the 990 HQ 2 25 How to Power Down the 990 HQ 2 25 Safety Controls 2 26 Emergency Shutdown and Recovery 2 26 To Resume Normal Operation after an E Stop 2 26 Air Brake on 990 HQ Eight Shooter 2 26 Summary of the Interface 2 28 Machine Control and Calibration Screens 2 28 Machine Feed Back 2 30 Controlling Access to User Screens 2 30 Main Screen 2 31 Main Screen ...

Page 7: ...creens 2 49 Calibration Slot 2 49 Dimensions of a Calibration Cut 2 49 Screen Details 2 50 Chisel Calibration 2 54 About the Pre Drill Screen 2 55 Entering Pre Drill Pattern Data 2 55 Example of Data Input 2 56 Diagnostic Screen 2 57 Status of I O and E Stops Screen 2 58 Appendix Machine Component Terms 2 60 ...

Page 8: ...KVAL 990 HQ Operation Manual Table of Contents ...

Page 9: ... 1 5 Lockout Tagout IMPORTANT Procedure to Lockout Tagout equipment when it is being serviced page 1 10 Zero Energy to Start Up Procedure to power up your machine for the first time page 1 12 Getting Help from KVAL This section describes the method to contact the KVAL service center for help The section includes how to get information from the specification plate tor provide to KVAL service center...

Page 10: ...Detailing Includes a servo driven ball screw and programming to automatically position and process one or two cylinder locks during the machine sequence The touch screen panel pro vides multiple standard lock layouts or custom locations from the numeric key pad The lock machining mechanism includes heavy duty drill motors mounted above and below the door to eliminate chipping door faces a separate...

Page 11: ...management functions such as Daily and Lifetime Totals When connected to the internet the PC allows remote support and monitoring of machine functions from Kval in Petaluma CA Door and jamb clamp reference The door will clamp downwards rather than upwards and the jamb reference will be to jamb stop top of H block not staging block for jamb edge This pro vides a consistent dimension between jamb we...

Page 12: ...s of Machine Line and Safety Information Chapter 2 Operation Interface Calibration Descriptions of how to power machine line and operator interface user screens Chapter Title Description Chapter 1 System IT Brief description of Computer and PLC in the Machine Chapter 2 Maintenance Maintenance steps for the machine line Chapter 3 Trouble Shooting Troubleshooting tips and theory of opera tion Servic...

Page 13: ...gy 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 warn...

Page 14: ...ine 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 t...

Page 15: ... 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 the electrical and air pressure systems This ...

Page 16: ...is 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 Saf...

Page 17: ... 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 lock a...

Page 18: ...ing 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 o...

Page 19: ... or repairs may started Post Maintenance Steps 9 After maintenance is completed the person performing the work must ensure all tools spare parts test equipment etc are completely removed and that all guards and safety devices are installed 10 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition...

Page 20: ...hen 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 compreh...

Page 21: ...y 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 22: ...ursday 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 m...

Page 23: ...ified 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 re...

Page 24: ... At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Google web ...

Page 25: ...me Field Enter your name The KVAL techni cian will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connection 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 26: ...How to Download the Service Application 1 18 990 HQ Operation Manual Page Intentionally Left Blank ...

Page 27: ... 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 ...

Page 28: ...Safety Sign Off Sheet 1 20 990 HQ Operation Manual ...

Page 29: ...ce Section Name Summary Page Operator s Tour Describes the operation machine Machine sections and assemblies are identified page 2 3 Quick Start A summary of the steps to machine a door page 2 21 Powering Operations for the 990 HQ Descriptions of power up power down homing and emergency stops page 2 24 Description of User Interface Screens Descriptions of the user interfaces Including Menu Maps of...

Page 30: ...tomatic control manual control functions can be implemented The machine also accommodates mixed stacks and automatic door positioning with a two speed feed belt sys tem Machine Orientation The Front Section refers to the side of the machine with the operator s station and includes the three Eight Shooter heads the front router motors the pre drills and chisels The Back Section refers to side of th...

Page 31: ... Carriage Head Left Out Feed Electrical Panel 2 Front Section 8 Shooter x 3 Operator s Station Option Located On Extend Arm ON Machine 8 Shooter Contains Hopper Screw Deliver System Screw Receiver Screw Driver Hydraulic System X3 Back Section Lock Bore Face Plate Assembly Control Box Lock Bore Contains Router Face Plate Drill Bolt Drill Drill x2 Drills lock hole on the face of the door Carriage He...

Page 32: ...with interfaces for an ON12 HQ Feeder Machine Controls Touch Screen LCD See Main Screen on page 2 31 Keyboard and Mouse are located on Oper ator s Table 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 Store Program To allow the operator to make changes to param e...

Page 33: ... 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 Eight Shooter heads will also begin to move into position Door Auto RH LH Select to receive either a left hand or right hand incom ing door Unclamp Use this button when performing a manual door run to unc...

Page 34: ...at the front of the machine Hinge Loaded Press after the Start Sequence button has been pressed and after the Eight Shooter heads have begun to move into hinge application posi tion This button informs the Eight Shooters that the hinges are loaded and ready to be applied Note Once the Hinge Loaded Button is selected do not enter the machine s active area ...

Page 35: ...inge jamb Hinge Head X3 Location of routers drills and chisels to machine hinge pockets The third hinge head routes a fourth pocket if desired Hydraulic Tanks for Eight Shooters Sup plies pressurized fluid for operation of the Eight Shooters In Feed The machine auto adjusts to in fed door Clamps and then sends door through machine for processing Eight Shooter X3 Auto loads hinges and fastens hinge...

Page 36: ...ur more servo motors ball screws and software control to adjust door positioning stops and the left and right hinge application heads Eight Shooter X3 Includes Hopper Screw Applicator and Screw Driver See About the Eight Shooter System on page 2 10 Operator Station See About the Operator Sta tion and Front Section Controls on page 2 4 Hinge Head X3 Loca tion of routers drills and chisels to machin...

Page 37: ... servo motor drives the head in highly accurate steps in the horizontal direction Servo Motor Y Axis Head x3 This servo motor drives the head in highly accurate steps in the vertical direction Servo Motor Z Axis Head x3 This servo motor drives the depth of the cut head in highly accurate steps See Connections to Servo Drives on page 6 30 This section supplies more information about the servo drive...

Page 38: ...stem Eight tubes that deliver the screws to the screw receiver for application to the jamb and door About the Hopper See the figure below for identification of Hopper assemblies Important Do not put Magnetized Screws in Hopper Magnetized screws can cause sluggish response to screws getting stuck Hopper plates could get magnetized and will have to be demagnetized with a degausser Important Do not a...

Page 39: ...h as well as both at the same time About the Eight Shooter System 2 11 990 HQ Operation Manual 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 Cyl inders to organize the screws and deliver them to the Screw Tracking Plate 4 The Ga...

Page 40: ...hange option to quickly change to dif ferent 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 ...

Page 41: ...ight 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 14 Hinge Application See About the Driver Assembly on page 2 14 Vertical Cylinder Drives Eight Shooter Up and Down the verti cal rails Spring Tensio...

Page 42: ... to set the depth of the screw drivers Used with the Forward Limit Switch Forward Stop Limit Switch Reverse Stop Limit on other side Plunge Cylinder Moves the screw drivers into place 8 Shooter Assembly Cylinders x2 Moves 8 shooter along rails to door and jamb Magnets x4 Magnets hold Hinge for Application Screw Receiver Tubes These tubes receive the screws from the hopper by way of plas tic tubes ...

Page 43: ... section process Includes faceplate routing and bolt boring on the edge of the door Includes a top lock and a bottom lock drill to drill the face of the two The two drills eliminates chip out Back Section See Front and Rear Views of the Back Section on page 2 16 FIGURE2 1 Key Assemblies on the Back Section ...

Page 44: ...e 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 t...

Page 45: ... 17 990 HQ Operation Manual About the Out Feed The door is automatically positioned to be fed into stacker Stationary Gate Dust Cleaner Movable Gate Main Air Input FRL Door FIGURE2 2 Key Assemblies on the Out Feed Section ...

Page 46: ...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 Frequ...

Page 47: ...Manual 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 Sec tion Input Output Terminals Servo Drives ...

Page 48: ...Q Operation Manual Description of the Six Light Panel The six lights on this panel indicate the status of the Architect DI system The Sequence that the lights activate is as follows 1 Control Power 2 Overload Relay 3 E Stop 4 Stop 5 Start 6 24VDC ...

Page 49: ...s are stacked in 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 Push the green START MACHINE buttons on all machines in the line Wait for the machine feedback on the operator screen dis plays Ready to Home Press the Hinge Loaded button to start the process Select the Home Machine Line But...

Page 50: ...se steps After the preset parameters are loaded the jamb spacer and 6 shooter pin values are displayed on the Main Screen Insert the displayed spacers on the H Blocks and the pin in the Eight Shooter assembly For pin and spacer locations see Hinge Spec Group on page 2 33 After the Home sequence is completed and door is fed in and clamped perform these steps 1 Load the jamb on top of ledge pressing...

Page 51: ...nge Loaded button to start the process 7 Repeat from Step Load Jamb until completed Note Be observant of the Status Blink Codes See Hinges Loaded Button Status Light on page 2 6 Machine Start Summary 2 23 990 HQ Operation Manual If Processing a Fourth Hinge If processing a fourth hinge the machine will move into position after the third hinge is com pleted After the position is set repeat the proc...

Page 52: ...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 HQ and the feeder CONTROL CIRCUIT switches to the ON position they all should light up Note Boot up may take 2 to 3 minutes Note Refer to the Feeder Stacker manual for informa tion specif...

Page 53: ...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 HQ is now ready for work How to Power Down the 990 HQ 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 ...

Page 54: ...esume 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 4 Re Home the machine and continue running the process Air Brake on 990 HQ Eight Sho...

Page 55: ...et the scanner then press the Home button on the Operator Interface If the scanner field is broken during this sequence the Screwdriver shift will stop and wait for you to reset the scanner before it starts again Screw Driving Sequence If the scanner field is broken during this sequence the Screwdriver will stop shifting and wait for you to reset the scanner before it starts again Once the screw d...

Page 56: ...een is also the startup screen for the 990 HQ From this screen all the basic user inter face controls are available to run a door See Main Screen on page 2 31 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 cal...

Page 57: ...ating the error code to machine sec tions or functions See Diagnostic Screen on page 2 57 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 58 Summary of the Interface 2 29 990 HQ Operation Manual ...

Page 58: ...isolate issues if having problems with the machine 1 2 3 4 Controlling Access to User Screens The 990 HQ 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 t...

Page 59: ...0 HQ Operation Manual Main Screen The Main Screen is also the startup screen for the 990 HQ From this screen all the basic user interface controls are available to run a door Main Screen Descriptions FIGURE2 4 Main Screen ...

Page 60: ... Use this button as part of the normal shutdown process See How to Power Down the 990 HQ on page 2 25 Preset Selection Button Group Pressing a preset button calls one of twelve presets stored in memory All the settings of the preset will populate the Main Screen entries Pressing the Modify Preset button allows the operator to store the active Main Screen entries After pressing the Modify Preset bu...

Page 61: ... on or off this function To set Pre Drill parameters see About the Pre Drill Screen on page 2 55 Length Displays the length of the hinge pocket Overall Height Displays the height vertical of the hinge pocket Backset Displays the space between the door edge and hinge Depth Displays depth Z axis of the hinge pocket Radius Displays the rounded corners of the hinge pocket Reveal The Reveal is set by t...

Page 62: ...ate or deactivate Hinge Head 2 Fourth Hinge Top Down The distance from the top of the door to the forth hinge edge Spacer Display This section displays the calculated H Block Spacer and 8 Shooter Pins to attach the machine The Spacers and pins are stored at the Operator s Station See below of location to put the spacers and pins on the machine See figure below for locations to install spacers and ...

Page 63: ...late Auto Enable and Disable Buttons From these buttons you can toggle auto functions on or off Auto Feed Press Auto Feed to toggle the auto feed on or off In auto mode the feed system will bring in and clamp a door wait for process 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 mach...

Page 64: ...n 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 FIGURE2 5 Manual Screen ...

Page 65: ...e 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 but ton Lock Location Group Reverse Press and hold the Reverse Button to move the position in reverse To stop release the button Forward Press and hold the Forward Button to move the position forward To stop release the button Speed S...

Page 66: ... and hold the Close button to close the width adjust carriage To stop the carriage release the button The carriage will also stop if the negative travel limit eye is activated Door Stop Press the Stop button to extend or retract the appropriate door stop Clamp Press Clamp to activate the cylinders that clamp the door Feed Reverse Press and hold the Reverse button reverse the feed of the door To st...

Page 67: ...oppers 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 39 990 HQ Operation Manual ...

Page 68: ...rrect 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 against all H Blocks 7 Ensure the door is clamped up tight against the reveal 8 Is the router or pre drill depth correct Use a Router Bit Depth Gauge PN 432C to check...

Page 69: ...About Calibration 2 41 990 HQ Operation Manual Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the 990 H FIGURE 2 6 Calibration Process Flowchart ...

Page 70: ...d 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 th...

Page 71: ...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 Eithe...

Page 72: ...ens drive the servo assemblies on the machine The servo motors are color coded for identification purposes Lock Section Servo Motor Carriage Servo Motors Door Jamb Stop Servo Motors Hinge Shift 3 Servo Motor Hinge Shift 1 Servo Motors Screw Shift 1 Servo Motors Screw Shift 2 and 3 Servo Motors X Offset Y Offset X Offset Y Offset Z Offset Z Offset ...

Page 73: ... and speeds The Setup Screen screen addresses the back section lock parameters and front section assemblies of the 990 HQ Press the Setup and Main Cal buttons to access this screen Tune the assem blies on this screen by entering and storing offsets to bring into reference Main Calibration Screen Descriptions FIGURE2 7 Setup Menu ...

Page 74: ...ock 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 Ena...

Page 75: ...een the period the door covers the before out feed eye and when the door clamps Longer times will allow the door to feed longer Screw Shift Offset See How to Enter Calibration Data on page 2 42 for instructions to enter calibration data The Screw Shift Offset should be calibrated from the inside out Calibrate the S2 S3 offsets first S3 next and finally S1 X Offset Y Offset X Offset Y Offset Setup ...

Page 76: ...s for Left Hand or Right Hand Doors The Right Hand Stops are located on the In feed while the Left Hand Stops are located at the Out feed This calibration tunes the servo motors for the Hinge locations of Head 1 and Head 3 X Offset Y Offset X Offset Y Offset Setup Screen 2 48 990 HQ Operation Manual ...

Page 77: ...ess 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 Calibration Slot This machine is equipped with a calibration routine that will Select the calibration routine from the Manual Screen to begin this calib...

Page 78: ...How to Enter Calibration Data on page 2 42 for instructions to enter calibration data Hinge Carriage Location Adjustments move the position of the carriage Pre Drill Router and Chisels Essentially this moves the all tool sets together as a unit up down across and into the jamb and the door ...

Page 79: ...X Y and Z direction Each pre drill hole moves the distance in the direction entered in the entry box This adjustment moves the pre drills only the chisels and the router will stay in the same position Jamb Door X Offset Y Offset X Offset Y Offset Z positive Offset plunges IN Z negative Offset retracts Out Setup Hinges 1 3 Screens 2 51 990 HQ Operation Manual ...

Page 80: ... 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 posi tion X Offset Y Offset X Offset Y Offset Jamb Door Z positive Offset plunges IN Z negative Offset retracts Out Setup Hinges 1 3 Screens 2 52 990 HQ Operation Manual ...

Page 81: ... servomotor driven and are calibrated remotely at the screens Perform the calibration of Hinge 2 first Hinge 2 is not driven by a servo motor but is driven pneumatically For the Hinge 2 calibration make mechanical adjustments and enter measurements calibration fields X Offset Y Offset X Offset Y Offset Hinge 2 location Non Servo driven Setup Hinges 1 3 Screens 2 53 990 HQ Operation Manual ...

Page 82: ...bration data Adjust the four corners of the hinges in the X Y and Z axis Upper Left Chisel Jamb Upper Right Chisel Jamb Lower Left Chisel Door Lower Right Chisel Door This adjustment moves the Chisels only the pre drill and the router will stay in the same position Jamb Door Upper Left Lower Right Lower Left Upper Right X Offset Y Offset X Offset Y Off set Z positive Offset plunges IN Z negative O...

Page 83: ...can adjust and store up to five pre drill screw patterns in memory Entering Pre Drill Pattern Data The X and Y valves are referenced off the bottom of the hinge on the door to the center of the hinge The jamb pre drill holes are equal to the mirror image of the parameters entered The number 0 entered in both X and Y are equal to no drill Name the Template Enter Drill Hole Locations ...

Page 84: ... 990 HQ Operation Manual 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 8 Pre Drill Samples ...

Page 85: ...lp 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 repre sentative This will aid in troubleshooting and shorten down time ...

Page 86: ...achine 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 o...

Page 87: ...ys real time feedback from the safety assemblies on the machine E Stop Verifies the activation and deac tivation of all E Stops Safety System Feedback from PLC Status of I O and E Stops Screen 2 59 990 HQ Operation Manual ...

Page 88: ... on the lock edge of the door Lock Bore The lock bore is located on the back section Drills a lock hole on the face of the door Pre Drills The pre drills are located in the Carriage Heads They pre drill screw holes for hinge screw application on the door and the jamb Chisels opt Chisels are located in the Carriage Heads and the back section The chis els square the corners on the hinge pockets and ...

Page 89: ...Appendix Machine Component Terms 2 61 990 HQ Operation Manual ...

Page 90: ...ency shutdown description 26 Exit Application 37 F front section key assemblies 8 front section status feedback 30 H high frequency panel description 18 high voltage electrical panel 18 hinge carriage user interface description 50 hinge heads locations terminology 8 hinge spec group description 33 home button description user interface 32 using 25 I input and output terminals location electrical p...

Page 91: ......

Page 92: ...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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