Kval 990FX Page 85 Operation Manual Download

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About the Electrical Panels

3-27

KVAL 990-FX Operation Manual

High Frequency Panels

The High Frequency Panel

• Supplies voltages to the machine
• Contains the PLC interface
• VFDs (Variable Frequency Drives) to interact with hinge and faceplate routers,

width adjust motors, and feed motors

FIGURE 3-19.

Overview High Frequency Panel

VFD Section

• Hinge Routere(1-4)
• Face Plate Router
• Feed Motor
• Width Adjust

120Vac / 24 VDC Terminals

PLC Interface
Input / Output Terminals

High Voltage Section

• Disconnect
• PDR
• Power Dist Connector
• Fuses

Contactors and Thermal

Over load Circuits

•  Lock Bore
•  Screw Drivers(1-4)
•  Bolt Drill

Summary of Contents for 990FX

Page 1: ...Innovation Quality Honesty Operation Manual Published September 28 2021 990 FX Pre Hanging Door System Includes Machines with Array Hoppers and Machines with RTS FX Hoppers 990 FX Service Manual ...

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

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 FX Operation Manual ...

Page 5: ...ut 1 10 Lockout Tagout Power 1 10 Lockout Tagout Air Supply 1 11 Start Maintenance 1 11 Post Maintenance Steps 1 11 Zero Energy to Start Up 1 12 Getting Help from KVAL 1 14 Kval Return and Warranty Policy 1 16 Send the Item 1 16 Acceptance of Return 1 16 Refund Turnaround Time 1 16 Kval Errors 1 16 Customer Errors 1 17 Shipper Errors 1 17 Warranty Replacement Parts 1 17 How to Download the Service...

Page 6: ... 2 19 2 20 About the Setup Screen 2 21 Machine with RTS FX 2 21 Enter a Positive or Negative Number 2 22 Entering Calibration Offsets 2 22 Calibration Steps for the Lock Location 2 23 Lock Location Calibration 2 23 Adjusting Lock Location 2 24 About the RTS Hopper Setup 2 26 Axis Direction 2 26 Diagnostic Screen 2 27 Chapter 3 Tour of the 990 FX Machine Component Terms 3 2 Common 990 FX Line Layou...

Page 7: ...17 About the Six Shooter System 3 18 About the Hopper 3 18 Hopper Process 3 19 About the Six Shooter Assembly 3 20 Six Shooter Hoppers on Machine 3 20 Six Shooter Hopper Array on Floor 3 21 Driver Assembly 3 22 About the Back Section 3 23 Back View of Rear Section 3 24 About the Out Feed 3 25 About the Electrical Panels 3 26 Main Electrical Panel 3 26 High Frequency Panels 3 27 About the Nodes 3 2...

Page 8: ...990 FX Operation Manual Table of Contents ...

Page 9: ... includes a general description and a table of available options page 1 2 Safety IMPORTANT safety information is described in this section page 1 4 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 specificat...

Page 10: ...both door and jamb Machine also includes automatic door width adjustment to accommodate mixed stacks and automatic door positioning with a two speed feed belt system Operation Door is automatically positioned while the operator loads and clamps the hinge jamb Routing and boring occur while the operator places hinges into the nests of the three hinge appli cators Pressing the In button fastens all ...

Page 11: ...door that can be machined to 18 Option I Reverse Feed Facing the hinge routers the normal feed direction is left to right Option IL Door Hand Indicator Light Light will be mounted on the out feed end of the 990 FX that can be seen by the 700 C Assembly Table operator The light will be on when the door in the 990 FX is being machined as a right hand door and off for a left hand door Option N Dust B...

Page 12: ...tion Descriptions of Machine Line and Safety Information 2 Operation Interface Descriptions of how to power machine line and use operator interface user screens 3 Tour of the Machine Highlights of the machine assem blies Chapter Title Description 1 Introduction Descriptions of Machine Line and Safety Information 2 IT System Description of the PLC of the machine 3 Maintenance Maintenance steps for ...

Page 13: ...ed or illegible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if the warning is not heeded it can cause death or serious injury CAUTION means if the precaution is not taken it may cause minor or moderate injury Safety Guidelines In addition to the caution and warning labels affixed to this machine fol...

Page 14: ...n Never perform any maintenance unless machine is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before ...

Page 15: ...ted at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out t...

Page 16: ...t If you believe any part or operation of this machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed safety guidelines are included in the operating instructions of this manual KVAL will be pleased to review with you any questions you may have regarding the safe operati...

Page 17: ...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 18: ... supply and pressure spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shutdown 3 Obtain locks keys and tags from your employer s lockout center 4 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to pop i...

Page 19: ...are completely removed and that all guards and safety devices are installed 10 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 11 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 12 The tags must be destroyed and...

Page 20: ... 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 21: ... 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 22: ... air print number 2 Contact our customer support team In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email address is service kvalinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30 AM to 1 30 PM Pacific Standard Time Friday What is the extent of the failure reason for return What are the ...

Page 23: ...was the application What was the system environment temperature spacing contaminants etc 3 Call KVAL Customer Support for a Return Material Authorization RMA When you call Have the packing slip or invoice numbers available Have the documented reason for return available 4 Send the merchandise back to KVAL Make sure the item s you are returning are securely packaged and well protected from shipping...

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

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

Page 26: ...m 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 w...

Page 27: ...rogram is ready to allow technicians to access machine computer Your Name Field Enter your name The KVAL tech nician will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connec tion to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support...

Page 28: ...How to Download the Service Application KVAL 990 FX Operation Manual 1 20 Page Intentionally Left Blank ...

Page 29: ...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 30: ...Safety Sign Off Sheet KVAL 990 FX Operation Manual 1 22 ...

Page 31: ... 990 FX Door Hanging System The content is geared to help operators understand the basic operation of the 990 FX Chapter 2 at a Glance Section Name Summary Page Powering the Machine Line Instructions To Powering The Machine Line page 2 2 Descriptions of the Interface Descriptions Of The Interface page 2 8 ...

Page 32: ...w to Power Up the Line 1 Ensure factory air is applied to each machine and main air supply is turned on 2 Check that all E Stop buttons are out and safety gates are closed 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 each electrical cabinet is turned to the ON position 4 Switch t...

Page 33: ...e Home button on the Main Screen touch screen 6 Initiate the Hinge Loaded to act as a Reset Note This process is a safety precaution to ensure the no personnel is in the machine staging area Push the Hinge Loaded Button 7 All lights on the status light panels on the electrical box should be illuminated Note If a status light does not turn on during the power up pro cess see the trouble shooting ch...

Page 34: ...n completely before turning off the machine Hard drive or data may be damaged if not turned off in this order 3 Switch the green Control Circuit switches for each machine to the OFF position 4 KVAL recommends to turn the disconnect switches located on the electrical cabinets to OFF Note This step helps reduce possible damage resulting from power surges from electrical storms Emergency Shutdown and...

Page 35: ...on 2 Turn on the Red Power Lever at each Electrical Panel 3 Turn on each Green Control Power Lever on the Operators Station 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 Press the Hinge Loaded button to start the process Select the Home Machine Line Button A...

Page 36: ...g split jambs enable the Split Jamb function RH Right Hand Door Auto Automatically receives data LH Left Hand Door After the machines have the Home sequence and door is fed in and auto clamped perform these steps While loading the jamb watch the place ment 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 pressi...

Page 37: ...e top of the door Each of the Six Shooter heads has a hinge pocket in which to place the hinge Note The hinge pocket is mag netic 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 ...

Page 38: ...e menu selections for the 990 FX Note Screen layouts may differ due to options that were ordered with the machine FIGURE 2 1 990 FX Menu Map Main Menu Opening Screen Set Presets to machine the doors See About the Main Screen on page 2 10 Manual Menu Control the machine manually through this screen See About Manual Operation on page 2 17 Setup Screen Calibrate the position of the lock location See ...

Page 39: ...t the bottom right hand cor ner of all user screens is status feedback information The information generated is as follows 1 General Machine Status 2 Front Section Status 3 Back Section Status 4 Current Servo Positions Note Use this information to isolate issues if having problems with the machine 1 2 3 4 ...

Page 40: ...the basic user interface controls are available to run a door For descriptions refer to the matching letter icon letter icon Note Screen layouts may differ due to options that were ordered with the machine Main Screen 4 Carriage Head with Array Hopper FIGURE2 2 Main Screen Note Call outs A and B are commonly used buttons and appear on all the screens ...

Page 41: ... 990 FX Operation Manual Main Screen 3 Carriage Head with RTS FX The controls are the same as a machine with an Array Hopper or integrated Hoppers with the exception of three Hopper buttons to represent each Hopper set on the RTS FX ...

Page 42: ...time the machine is powered up or reset If a fault occurs that cannot be cleared press the Reset but ton This button will reset the machine to the start position before homing Note Press Home Machine after Reset Machine This button stops the door in the process This button shuts down the computer Use this button as part of the shutdown pro cess See Initial Powering Operations for the 990 FX Line o...

Page 43: ...ter machining is completed Auto Width Press Auto Width to toggle the auto width on or off In auto mode the sys tem will auto adjust to the width of the door that is being processed Jump Buttons These buttons allow movement to each screen Main This Section Manual See About Manual Operation on page 2 17 Setup See About the Setup Screen on page 2 21 Diagnostics See About the Setup Screen on page 2 21...

Page 44: ...ry Head 2 Router Routers Press to Enable or Disable the Routers in Head 2 On a machine with 4 Carriage Heads disable to create 3 hinged door Three Head Machines Heads 1 and 3 can be disabled as a pair Head 2 can be disabled by itself Note Review Calibration aspects of the Hinge groups see Screw Shift on page 2 25 Hinges Group Set the parameters for the hinges in the Hinge Spec group Push desired b...

Page 45: ...hooters Option Split Jamb Stapler Press to Enable or Disable the Split Jamb Stapler For more information see Option H Securing Split Jambs on page 3 32 Hinge Modes with RTS FX Machine with an RTS FX include buttons that identify each hopper set The button labels are set at the RTS FX setup screen See About the RTS Hopper Setup on page 2 26 Note This example shows the Load button and Manual Air Inj...

Page 46: ...ess the Lock Bore button to enable or disable the Lock Bore Bolt Drill Press the Bolt Drill button to enable or disable the Bolt Drill Face Plate Press the Face Plate button to enable or disable the Face Plate Lock Backset indicates the backset distance for the each downloaded preset Ball Catch Option Press to Enable or Disable the Ball Catch Lock Group In the Lock Group the back section machining...

Page 47: ...on At this screen control certain functions of the machine in manual mode This screen is mainly used in troubleshooting checking cut specifications and maintenance Note Screen layouts may differ due to options that were ordered with the machine FIGURE 2 3 Manual Operation Screen ...

Page 48: ... The carriage will also stop if the negative travel limit eye is activated Feed Manual Control Feed Reverse Press and hold the Reverse button reverse the feed of the door To stop the feed release the button Forward Press and hold the Forward button to move the door feed forward To stop the feed release the button Normal Speed Press and hold the Normal Speed button to slow speed To return to previo...

Page 49: ...desired speed and press OK when finished Burn Chipout Use this button if a new Chipout Block is installed on the lock section Press to start the burn sequence A new hole will be slowly drilled the process will automatically stop when finished Hinge Manual Control Hinge Carriage Location Up Press and hold the UP button move the Hinge Carriage up Release the button to Stop Jog Down Press and hold Do...

Page 50: ... Drive screws through tubes Shift Drivers In Out The In button shifts the six shooters over hinges The Out button shifts the six shooter out of position Test Mode and Hinge Burn Chipout Command Code Displays current command code Activate Command Press to activate the command code in the box Test Mode Select to toggle the Test Mode on or off Test Mode runs the hinge cycle but does not extend the to...

Page 51: ...ck carriage in the X Y and Z direction Use this screen if the parameters of the rear machining is not in specification Note Screen layouts may differ due to options that were ordered with the machine Machine with RTS FX Machines with a RTS FX Hopper includes a separate calibration page Select the RTS Hopper Setup button to jump to the calibration screen See About the RTS Hopper Setup on page 2 26 ...

Page 52: ...xpected result Use this number to enter into the offset box under the inaccurate parameter Note Maximum offset is 0 50 inches If more than 0 50 inches of adjustment is needed there is a high probability that another issue may be causing a problem If issues can not be resolved contact the KVAL Service Center KVAL Inc 1 800 553 5825 See Getting Help from KVAL on page 1 14 5 Run a test door again to ...

Page 53: ...ibration sets the distances of the LH and RH Stops from the Home Limit as a reference 6 8 to 8 0 Tunes the distance of the stops from the refer ence HOME for LH and RH doors of each door length Note Door lengths may vary per option selection To start run a known good lock cut at a standard location on a Right Hand or Left Hand door Once the lock cut is completed check the distance from the top of ...

Page 54: ...ck cut 6 Measure again and repeat steps 3 to 4 until the center of the lock is at the desired cut location 7 Once the completed with calibration select the Combine with Base button to store the data 8 Exit Main Calibration Screen Timing Front Section and Back Section Use the Timing Controls to tune the synchronization of the Carriage Head routine and the Face Plate routine If Either process is fin...

Page 55: ... eye Screw Shift Adjust the Screw Shift locations for Four Head Machines Heads 1 2 are paired and Heads 3 4 are paired Three Head Machines Heads 2 and 3 are paired The Out parameters correspond to the Heads when they are parked and out of the way The In parameters correspond to Heads when they are located in the middle of the machine getting ready to pro cess the door Head 1 and 2 Head 3 and 4 Bac...

Page 56: ...S FX can also be adjusted Axis Direction Hopper Names Enter a descriptive name to identify the Hopper This label will be dis played on the Main Screen All Hoppers Calibrate all Hoppers as a set Hopper Sets 1 through 3 Calibrate each Hopper set individually A positive number moves the Hopper in the Clockwise direction For more information about using the calibra tion boxes see Entering Calibration ...

Page 57: ...ine 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 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...

Page 58: ...of doors pro cessed through out the day This is additive until reset Reset Count Push to reset the Daily count of doors The Door Count box keeps track of all doors processed on the machine and the daily count of doors processed The Total door count cannot be reset The Daily count can be reset Use the daily count to keep track of the throughput of daily manufacturing ...

Page 59: ...990 FX Chapter 3 at a Glance Section Name Summary Page Common Terms Table of Common Terms page 3 2 About the Machine Line General Information About The Machine Line page 3 3 Summary of Machine Controls Description Of The Machine Line Controls page 3 7 Safety Controls A Summary Of The Safety Controls On The Machine Line page 3 2 Tours of the Machines A Summary Of The Machine Assemblies page 3 2 ...

Page 60: ... 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 the loc...

Page 61: ...r is placed onto the powered roller The door is fed into the 990 FX automatically or with a call door function After the door is fed into the 990 FX the action is repeated For a detailed description of the Feeder see the Feeder Operation Service Manual Note Feeders may vary common Feeders are the ON 3 series the Handler series The 700 C IA strike jamb and Header are placed into the machine A proce...

Page 62: ...y Hopper The illustration blow depicts a machine with 4 Carriage Heads Hopper 2 Hopper 4 Hopper 3 Hopper 1 Operator s Station Six Shooter 4 Option Six Shooter 2 Six Shooter 3 Six Shooter 1 Carriage Head 4 Option Carriage Head 3 Carriage Head 2 Carriage Head 1 Electrical Panel 1 Out Feed Front Section Back Section In Feed Path of Hinge Screw through tubes Air Tank Lock Bore Assembly Light Curtain T...

Page 63: ...age Heads Electrical Panel 1 Out Feed Operator s Station Hopper B Hopper A Front Section Back Section Six Shooter 2 Six Shooter 1 Hopper C Lock Bore Assembly Six Shooter 3 Carriage Head 1 Carriage Head 2 Carriage Head 3 Air Tank RTS FX To Six Shooters To Six Shooters To Six Shooters Out Feed Light Curtain Transmitter Light Curtain Receiver ...

Page 64: ... Motor Assembly and Rotate Gear Assembly Air Solenoid Bank Manifold Not Shown Adjustable air pressure to drive screws to Hopper The RTS FX is A companion station for the 990FX allowing up to three sets of screw hoppers to automatically index for screw color change Three sets of screw hoppers to rotate in 90 degree increments controlled by a servo motor and gear system Screw feed hoses 18 from the ...

Page 65: ...stem Operator Station Touch Screen Interface Main Control of the 990 FX Auto load and run predetermined parameters on doors Manually control the door path and process through the line Machine diagnostics are included as well as internet support and connectivity for remote support via our Service Support Main Control Panel Power Up and Power Down machines Start and stop the door process See Machine...

Page 66: ... parameters such a presets and cal ibrations Note Locked out parameters may vary due to customer preference Start Machine Button Wakes up the machine similar to a boot up Stop Machine Button Puts the machine to sleep Control Power Energize and De Energize the machines Lock Lock out access to Adjust ment E Stop push to shut down machine in an emergency situa tion To allow the operator to make chang...

Page 67: ...aded and hands are safely out of the way Note Be prepared for the front section routers to move into position and begin routing as well as the back section routers lock bore and bolt drill The Six Shooter heads will also begin to move into position Door Auto RH LH Press for Auto Run or to receive either a left hand or right hand incoming door When in Auto Door mode the 990 FX receives information ...

Page 68: ...3 10 Hinges Loaded Button Light Curtain Status Light The Hinge Loaded button is located on the Light Curtain frame Hinges Loaded Step out of the Safety Light Curtain and press this button after hinges are loaded on to the Hinge Applicators The Light Curtain will be activated ...

Page 69: ...t Curtain The Safety Light Curtain provides safety for personnel who enter the defined area when the machine is active If any part of an operator s body is detected in the defined area the machine stops the operation The machine must be reset from the operators station to continue machining The Safety Light Curtain is composed of an EZ Screen emitter and receiver The emitter has a row of synchroni...

Page 70: ...n after an Beam is Broken If a Beam is broken use the following procedure to recover Status Indicator and Hinges Loaded Reset Breaking of any beam stops the machine Machine in operation Emitter Receiver 1 1 Push the START MACHINE button on the operator s station 2 Press the Hinge Loaded Button 3 Home the Machine 2 ...

Page 71: ...er assemblies The brakes will lock the six shooter in place avoiding a crash to the head The brakes are controlled by a lack of air pressure and will lock when the air pressure drops below a reference level Brakes are located on each side of the six shooter assemblies Bypass valve will bypass air causing the brakes to lock ...

Page 72: ...3 9 Key Assemblies on the In Feed Section Lock Back Section Faceplate routing and boring for lock and bolt In Feed System Door is delivered from previous machine and fed into 990 FX for process ing Hydraulic Tanks for Six Shooters Supplies hydraulic pressure to operate Six Shooter Six Shooters Auto drop down to apply hinges and secure them with screws delivered from Hopper Six Shooter Nodes Wiring...

Page 73: ... and door edge Carriage Heads pre drill pilot holes for Hinge application Hoppers deliver screws to Six Shooters by way of a air tube Six Shooters drop down and drill hinge into place on jamb and the door edge FIGURE 3 10 Front Section Carriage Head 1 Carriage Head 2 Carriage Head 3 Screws Transported Six Shooter 1 Carriage Head 4 Six Shooter 2 Six Shooter 3 Six Shooter 4 Hopper 1 Hopper 2 Hopper ...

Page 74: ...r Option When Processing a 6 8 and a 7 0 Door Six Shooter 1 and Carriage Head 1 are put in the parked position and not used Six Shooters and Car riage Heads 2 4 are used to process the door When processing 8 0 doors all Carriage Heads and Six Shooters are used to process a door ...

Page 75: ... a hinge pocket on the door and jamb A pre drill to drill pilot holes in the hinge pockets to ready the insertion of screws by the six shooter Pre Drill Drills pilot holes for insertion of screws on the jamb and the door Air Driven Router Routs the hinge pocket on the jamb and the door at the same time as the counter rotate router Pre Drill Router Door Predrill Bits Jamb Predrill Bits ...

Page 76: ...t the Hopper Review to the figure below for identification of Hopper assemblies See Hopper Process on page 3 19 for operation descriptions FIGURE 3 11 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 pleas...

Page 77: ...ome Six Shooter Systems have an a quick change option to quickly change to differ ent colored screws To start the quick change process 8 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 9 Once the Hopper is in the up position the door will ope...

Page 78: ...ace Door is automatically positioned while the operator loads and clamps a hinge jamb Routing and boring occur while the operator places hinges into the nests of the hinge applicators Six Shooter Hoppers on Machine FIGURE 3 12 Six Shooter Call Outs Hoppers on machine Horizontal Rails Allows the Six Shooter to the move to the side for Maintenance and Manual application of Hinges Vertical Rails Tube...

Page 79: ...he move to the side for Maintenance and Manual application of Hinges Vertical Rails Tube Frame Delivers Screws to Hinge Applicator by way of plas tic tubes Driver Assembly Hinge Application Vertical Cylinder Drives Six Shooter Up and Down Spring Tension for vertical movement Note Air brakes are located on the verti cal rails The brakes will operate when air pressure goes down a set reference level...

Page 80: ...Index Spacers X2 Factory set to align hinge Screw Receiver Tubes These tubes receive the screws from the hopper by way of plastic tubes Latch Arm Latches to H Block to secure in place Latch Arm Cylinder Moves latch arm in and out of position 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...

Page 81: ... Works in partnership with front section process Includes faceplate routing Includes boring for lock and bolt Front View of Rear Section FIGURE 3 15 Key Assemblies on the Back Section View from Front Section Back Section Valve Bank Lock Bore Motor and Drill Drills locks holes on the face of the door Chip Out Location Lock Bore Bolt Drill Motor Machines Hole for Bolt Self Centering X axis Centers t...

Page 82: ...6 Key Assemblies on the Back Section Back View Bolt Drill Extend and Retract Cylinder Oil Reservoir Lock Bore Extend and Retract Cylinder Lock Bore Limit Switches Face Plate Motor and Drill Routs face plate Edge Clamp Clamps edge of door Edge Clamp Clamps edge of door Deep Shallow Retracted ...

Page 83: ... send out door FIGURE 3 17 Key Assemblies on the Out Feed Section Opt N Dust is blown off by com pressed air Valve Bank Back Section Air Input System Out Feed System The processed Door is fed to the next machine Sen sors detect position of door and when to send it out Hydraulic Tanks for Six Shooters Supplies hydraulic pressure to operate Six Shooter Front Section ...

Page 84: ...ame Note Some Options may include a Main Power Distribution Panel This panel accepts factory power and distributes to the Main Electrical Panel and the High Frequency Panel See your machine schematics tor more information Main Electrical Panel The Main Electrical Panel Supplies voltages to the machine Contains the PLC Programmable Logic Controller Contains servo drives to interact with the servo m...

Page 85: ... to interact with hinge and faceplate routers width adjust motors and feed motors FIGURE 3 19 Overview High Frequency Panel VFD Section Hinge Routere 1 4 Face Plate Router Feed Motor Width Adjust 120Vac 24 VDC Terminals PLC Interface Input Output Terminals High Voltage Section Disconnect PDR Power Dist Connector Fuses Contactors and Thermal Over load Circuits Lock Bore Screw Drivers 1 4 Bolt Drill...

Page 86: ...aces from the Main E Box Node contain inputs and outputs of PLC and power connections For example door sensors width adjusts and tool interfaces FIGURE 3 20 Sample of a Frame Node PLC Interface Top Ethernet cable is from PLC Bottom Ethernet goes to Cutter Node Inputs and Outputs Interconnect Bar ...

Page 87: ... 21 Location of Nodes on Machine Main E Box Contains Servo Drives Network Connections power and Inputs Outputs originate at this box and are connected to Nodes Network Connections Power Distributed to Points in the machine High Freq Box Power Distributed to Points in the machine Frame Node Screw Driver 1 Screw Driver 2 Screw Driver 3 Screw Driver 4 Back Section Node ...

Page 88: ...and right hand doors for drive in ball catches When selected the proper drill automatically pivots in to drill into the top of the door minimum door width for drilling is 18 FIGURE3 22 Location of Ball Catch Drills Option N Dust Blow off System Air blow off tube cleans dust and chips from the top of a door Located on the Outfeed of machine FIGURE3 23 Air Blow off Front of Machine Ball Catch Left H...

Page 89: ...oor Stop for 8 0 doors Air Cylinder for Hinge Router Shifts for 6 8 8 0 Retractable Six Shooter for loading in jambs servo motor driven About the Shift Function The Shift In Function moves Car riages 1 2 3 and 4 into working posi tion Shift In Shift Out The Shift Out Function moves Car riages 1 2 3 and 4 into a position to allow the operator into the machine processing area Allows the operator to ...

Page 90: ...gle valve that is interlocked with a safety switch to disable the staple guns unless there is a jamb clamped in the machine To Use this Function 1 Enable by selecting the Split Jamb Stapler button Green Located on the Main Screen 2 Load the male split jamb into the female slot of the jamb 3 Load jamb assembly into machine 4 During process The split jamb auto triggers the firing mechanism of the st...

Page 91: ...nging hoppers for changing screw colors Enables the operator to change or add screws at floor height Set up containers to catch the screws 1 Select the Manual Screen Tab 2 Press the Quick Dump Hopper Button 3 Pour new screw style into each hopper 4 Continue processing doors Dump Area ...

Page 92: ...peration Manual 3 34 Description of the Six Light Panel The six lights on this panel indicate the status of the Commander III 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 93: ... shutdown description 2 4 3 11 F front section key assemblies 3 17 front section status feedback 2 9 H high frequency panel description 3 27 home button description user interface 2 12 using 2 3 I input and output terminals location electrical panels 3 27 L lock calibration 2 23 lock access to user screens 3 8 lock location adjusting location 2 24 lockout and tagout Guidelines 1 12 lockout procedu...

Page 94: ...afety Concerns 1 21 servo positions feedback 2 9 setup screens 2 21 shut down system description user interface 2 12 six light panel description 3 34 sequence list 3 34 start machine button power up 2 2 stop sequence button description user interface 2 12 T tagout procedure 1 10 U user interface screens menu map 2 8 Z zero energy start up clean up 1 12 inspect 1 12 ...

Page 95: ......

Page 96: ...upport Department Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL Phone and Fax In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email service kvalinc com http www kvalinc com ...

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