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Kval 990-H Service Manual

Pre-hanging door system
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Innovation, Quality & Honesty
990-H Pre-Hanging Door System
Service Manual
Published: 2/2/15

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Summary of Contents for Kval 990-H

  • Page 1 Innovation, Quality & Honesty 990-H Pre-Hanging Door System Service Manual Published: 2/2/15...
  • Page 2 Proprietary Notice This Manual is confidential and contains proprietary information and intellectual property of KVAL Inc., and is to be used solely by Customer as an operating manual for KVAL Inc. machines. Neither this Manual nor any of the information contained herein may be reproduced or disclosed under any circumstances without the express written permission of KVAL Inc.
  • Page 3 KVAL 990-H Service Manual Your Feedback is Welcome: To help us design products that make your job easier and your business more successful, we'd like to gain your perspective about your user experience with our product - that is, the manual, the machinery, the software, etc.
  • Page 4 KVAL 990-H Service Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction to the 990-H Door Hanging System Chapter 1 Chapter 1 at a Glance.............. 1-1 Overview of the 990-H 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...
  • Page 6 Replacing Bits................2-13 Replacing Bits in the Front Section ............2-13 How to Access to Bit Assemblies ............2-14 Remove and Replace the Screwdriver Bits ........2-16 Mechanical set up of the 990-H ..........2-18 Back Section..................2-19 Trouble Shooting of the 990-H Chapter 3 Network System Overview............

  • Page 7: Chapter 1 At A Glance

    CHAPTER 1 Introduction to the 990-H Door Hanging System This chapter provides an overview of the KVAL 990-H Door Hanging System and important safety information to follow when operating the machine. Chapter 1 at a Glance Chapter 1 at a Glance ..................

  • Page 8: Overview Of The 990-H Door Hanging System

    KVAL's 990-H is the fastest and most productive pre-hanging system available in the industry. The 990-H will rout and chisel a door and jamb for three hinges, drill pilot holes for the hinge screws, mortise for the lock, and apply three hinges. This machine is generally used in conjunc- tion with the ON-2012 for in-feed and out-feed operations.

  • Page 9: Safety First

    • 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 the 990-H system, follow the guidelines below to help ensure the safety of equipment and personnel. Training...
  • Page 10 Before performing any mainte- nance or repairs on this machine turn off the main air disconnect. Lockout and tagout this connection. See “Lockout Tagout Procedure” on page 1-7. KVAL 990-H Service Manual...
  • Page 11 Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tag out, or lock out the elec- trical and air pressure systems. This should be done in accordance with applicable state and/ or federal code requirements. KVAL 990-H Service Manual...
  • Page 12 Safety First! Compliance with Codes and Regulations KVAL advises that you request an on-site state safety review of your installation of this machine. This is to ensure conformance to any additional specific safety and health regula- tions which apply in your geographic area.

  • Page 13: Lockout Tagout Procedure

    This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991. Use the following lockout procedure to secure the 990-H while it is powered down. During a lockout, you disconnect all power and shut off the air supply. Be sure to use the tagout guidelines noted below.
  • Page 14 • If more than one person is working on the machine, then each additional person places a lock and tag on each disconnect. • Only each operator may remove their own lock and tag. KVAL 990-H Service Manual...

  • Page 15: Follow The P-R-O-P-E-R Lockout Rule Of Thumb

    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 KVAL 990-H Service Manual...

  • Page 16: Zero-Energy To Start-Up

    Replace Guards Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the KVAL Service team. See “Contacting KVAL” on page 1-2. Check Controls Confirm that all switches are in the “OFF”...
  • Page 17 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. 1-11 KVAL 990-H Service Manual...

  • Page 18: Getting Help From Kval

    Chapter 3 “System IT Administration” on page 3-1, for more information. 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 machine or part.
  • Page 19 • With what equipment is the unit interfaced? • What was the application? • What was the system environment (temperature, spacing, contaminants, etc.)? Call Kval customer support for a Return Material Authorization (RMA). When you call: • Have the packing slip or invoice numbers available.

  • Page 20: Safety Sign-Off Sheet

    It is recommended you make a copy of this sheet for new operators. If a copy is Note: 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 service@kvalinc.com.
  • Page 21 Safety Sign-Off Sheet 1-15 KVAL 990-H Service Manual...
  • Page 22 Safety Sign-Off Sheet 1-16 KVAL 990-H Service Manual...

  • Page 23: Chapter 2 Maintenance Of The 990-H

    CHAPTER 2 Maintenance of the 990-H This chapter describes preventative maintenance steps for KVAL 990-H. The content is geared to guide technicians to keep a regular maintenance schedule for your KVAL machine. Keeping your KVAL machine maintained is an important piece for successful operation of your door production process.

  • Page 24: Operator's Tour

    Operator’s Tour Operator’s Tour This section takes you on a tour of the 990-H Pre-Hanging Door machine. The 990-H is part of a system that includes an automatic door feeder and door loader to provide a full door processing system. Refer to Figure 1 below, for locations of the assemblies described in this section.

  • Page 25: 990-H Machine Tour

    Operator’s Tour 990-H Machine Tour The 990-H can be paired with different feeder and stacker model numbers. This manual assumes the ON-2012 as a feeder and stacker. These machines are addressed in separate manuals. 990-H Door Hanger ON-2012 Stacker ON-2012 Feeder The 990-H Door Hanging System FIGURE 2- 2.

  • Page 26: Maintenance Schedule

    Maintenance Schedule Maintenance Schedule KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Refer to this section for steps to perform maintenance. Recommended Lubrication Schedule TABLE 2-1. Type of Assembly Recommended Schedule Recommended Lubrication Type Linear Bearing...

  • Page 27: Weekly

    Adjustment knob Tightening nut • Check all air lines & electrical wiring for kinks or rubbing. • Refill lubricator with an ISO 32 standard hydraulic oil (use KVAL part# SYS- LUBEG). Six Month Checkups • Wash filter and lubricator bowls with soapy water.

  • Page 28: Lubrication Requirements

    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. Bearings without grease fittings have been pre-lubricated at the factory and do Note: not require further lubrication.

  • Page 29: Gear Motor Lubrication Requirements

    MOBILUBE HD 80 W-90 or equivalent. Ball Screws All ball screws should be lubricated Dura-Lith Grease (KVAL P/N Lube EP-2) for every 80 hours of operation. At each lubrication grease should be pumped into the fitting until clean grease comes out around the ball screw.

  • Page 30: Adjusting The Air Line Lubricator

    Repeat this same procedure for the back section and other trouble areas. It is recommended to check the lines every week to two weeks. KVAL 990-H Service Manual...

  • Page 31: Lubrication Points On The 990-H

    Lubrication Points on the 990-H Lubrication Points on the 990-H Feed System Lube Points Use Lube-EP2 (or similar) to Lubricate Chains Lubricate feed sys- tem hex shaft with Silicon Spray Feed System Lubrication Points FIGURE 2- 6. KVAL 990-H Service Manual...

  • Page 32: Screw Driver Lube Points

    Lubrication Points on the 990-H Screw Driver Lube Points Screw Drive Lubrication Points FIGURE 2- 7. 2-10 KVAL 990-H Service Manual...

  • Page 33: Back Section Lube Points

    Lubrication Points on the 990-H Back Section Lube Points Back View Front View Back View 2 Bottom View FIGURE 2- 8. 2-11 KVAL 990-H Service Manual...

  • Page 34: Head Lube Points

    Lubrication Points on the 990-H Head Lube Points Bottom Back 1.Assemblies shown transparent. FIGURE 2- 9. 2-12 KVAL 990-H Service Manual...

  • Page 35: Replacing Bits

    Replacing Bits Replacing Bits The 990-H is a powerful electro-mechanical motion Caution control system. If servicing the 990-H follow the safety guidelines described in. Failure to do so can result in damage to equipment and/or serious injury to personnel. 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...

  • Page 36: How To Access To Bit Assemblies

    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 Removing Pre-Drill or Router Bit. FIGURE 2- 11. 2-14 KVAL 990-H Service Manual...
  • Page 37 Drill Depth Router Depth Set to 2.0” Set to 1 3/4 “ 1 3/4 ““ 2.0 “ Router Bit Depth Gauge Setting the Bit Depths FIGURE 2- 13. 2-15 KVAL 990-H Service Manual...

  • Page 38: Remove And Replace The Screwdriver Bits

    To replace screwdriver bits on the Six-Shooter heads, follow the instructions below. Turn off all power to the machine. Follow proper lockout/tagout procedures as detailed in the safety section of Chapter 1 of this manual. 2-16 KVAL 990-H Service Manual...
  • Page 39 Release holder to secure bit. Move Six-Shooter assembly back toward machine and pull the back slide toward you; then move assembly away from machine to restore assembly to original start- ing position 2-17 KVAL 990-H Service Manual...

  • Page 40: Mechanical Set Up Of The 990-H

    Repeat step 1-3 until hinge centers are to you specifications. Setting Up the Hinge Backset The hinge backset on the 990-H is controlled by two positive stop bolts on each of the three routing carriages. 2-18 KVAL 990-H Service Manual...

  • Page 41: Back Section

    • Re-tighten the lock nut so the bolt does not move out of place. Setting the Doorstops The 990-H comes equipped with two door stops; one for right hand doors and one for left hand doors. The doors stops accurately position the door so that the hinge loca- tions are consistent.
  • Page 42 Mechanical set up of the 990-H Once the router shifts out of the pocket and hits the limit switch and the lock bore gets to the retracted limit switch. the bolt drill will then move inward. Check to ensure the cycle performs as previously stated. Look for sticking or uneven movement of each assembly.
  • Page 43 Setting Up Lock Bore Backset The lock bore backset (the distance from the center line of the lock bore to the door's edge) is controlled by four adjustable turret stops. KVAL's factory setting for the lock bore turrets accommodates 5", 2.75" and 2.375".
  • Page 44 The turret bolts should never be adjusted, since these were micrometer-set at the factory. If both the plate and latch hole are off-center, contact KVAL for instructions on Note: shimming the self-centering clamp system.

  • Page 45: Chapter 3 Trouble Shooting Of The 990-H

    Trouble Shooting of the 990-H This chapter describes troubleshooting steps to help technicians solve issues that may occur with your KVAL machine. If help is needed, call or contact our KVAL Service team at (800) 553-5825 or http://www.kvalinc.com. Chapter 3 at a Glance Network System Overview ................

  • Page 46: Network System Overview

    Figure 3- 15 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.

  • Page 47: Connections To Servo Drives

    To Servo Motors for Head #2 Y-Axis and Head # 2 Z-Axis Servo Drive 3 To Servo Motors for Head #3 X-Axis and Head # 3 Y-Axis Servo Drive 5 To Servo Motors for Head # 3 Z-Axis and Lock Location X-Axis KVAL 990-H Service Manual...

  • Page 48: High Frequency Panel Node Connections

    High Frequency Node Inputs and Outputs TABLE 3-3. Call Input Designator Call Output Designator I-6030 to I-6037 Q-6030 to Q-6037 I-6020 to I-6027 Q-6020 to Q-6072 I-6010 to I-6017 Q-6010 to Q-6017 I-6000 to I-6007 Q-6000 to Q-6007 KVAL 990-H Service Manual...

  • Page 49: Frame Node Connections

    This node includes frame related inputs and outputs including head limits, jamb controls, foot control, and control of door through machine. See “Location of Sensors on 990-H” on page 3-10 for locations of frame input sensors. For general information, refer to Figure 3- 18 and Table 3-4.

  • Page 50: Back Section Node

    PS 1 and PS 2 Back Section Node FIGURE 3- 18. Back Section Inputs and Outputs TABLE 3-5. Call Input Designator Call Output Designator I-5000 to I-5007 Q-5000 to Q-5007 I-5010 to I-5017 Q-5010 to Q-5017 KVAL 990-H Service Manual...

  • Page 51: Screw Driver Nodes 1-3

    Node # 3 Node # 2 Node # 1 Outputs Screw Driver Nodes FIGURE 3- 19. TABLE 3-6. Screw Driver Node # 1 Call Input Designator Call Output Designator I-2001 to I-2007 Q-2000 to Q-2007 Q-2010 to Q2017 KVAL 990-H Service Manual...
  • Page 52 TABLE 3-7. Call Input Designator Call Output Designator I-3000 to I-3007 Q-3000 to Q3007 I-3010 to I3017 Screw Driver Node # 3 TABLE 3-8. Call Input Designator Call Output Designator I-4000 to I-4007 Q-4000 t o Q-4007 KVAL 990-H Service Manual...

  • Page 53: About Sensors

    About Sensors About Sensors On the 990-H, sensors provide input to the PLC as part of the automation of the door cutting pro- cess. It is important to keep the sensors cleaned and aligned to keep the door process running smoothly.

  • Page 54: Location Of Sensors On 990-H

    About Sensors Location of Sensors on 990-H Figure 3- 21 below, shows the sensor locations on the 990-H The “I” designation represents an input to the PLC and the “Q” designation represents an output from the PLC. Door Sense Eye...
  • Page 55 Y-Axis Reverse Crash Eye (I-1034) (I-1054) (I-1014) Y-Axis Forward Crash Eye Y-Axis Forward Crash Eye Y-Axis Forward Crash Eye (I-1035) (I-1055) (I-1015) Figure 3- 22 Section View of 990-H Y Axis Sensors FIGURE 3- 22. 3-11 KVAL 990-H Service Manual...
  • Page 56 (I-1057) (I-1037) Z-Axis Forward Crash Eye Z-Axis Forward Crash Eye Z-Axis Forward Crash Eye (I-1020) (I-1060) (I-1040) Hinge #3 Hinge #2 Hinge #1 Bottom View of 990-H location of Z Axis Sensors FIGURE 3- 23. 3-12 KVAL 990-H Service Manual...

  • Page 57: Troubleshooting Electrical Problems

    Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Test Panel. If cop- NOTE: ies are unavailable, contact the KVAL Service Department. Have model number and serial number of machine readily available. The following checks require the electrical panel to be Warning energized.

  • Page 58: Troubleshooting With The Status Light Panel

    STEP 6: 24VDC (Greening light is OFF go to item on page 3-17. The following checks require the electrical panel to be Warning energized. These troubleshooting checks must be per- formed by a Qualified Electrical Technician. 3-14 KVAL 990-H Service Manual...

  • Page 59: Control Power Light Off

    Check to see the if any E-Stop buttons are pulled out.  and quantity of E-Stop buttons varies depending NOTE: Location on customer need. Typical locations for E-Stop buttons are near the Rear Access Gate and near the Tool Changer Access Gate 3-15 KVAL 990-H Service Manual...

  • Page 60: Stop Light Off

    Start button and hold it in while a second person checks for voltage between #2 and #5. If there is 110 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wir- ing. 3-16 KVAL 990-H Service Manual...

  • Page 61: 24Vdc Light Off

    Reinstall the + brown wires one by one checking for +24VDC after installing each + brown wire. If at any point no voltage is found trace the last reinstalled wire and check for shorts. 3-17 KVAL 990-H Service Manual...

  • Page 62: Troubleshooting The Air Cylinders

    Check the flow controls to see that they are adjusted correctly and to the proper specifications. Check for any obstructions to the cylinders such as Manual over- ride button screws or a misplaced tool etc. FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS. 3-18 KVAL 990-H Service Manual...
  • Page 63 It might be necessary to call in a specialist or check with KVAL customer service at 1- 800-553-5825. If an Air Leak is coming from an exhaust port on the solenoid air bank: a.Check the solenoid for the manual override.

  • Page 64: Adjusting Cylinder Extension Speed

    Troubleshooting the Air Cylinders Adjusting Cylinder Extension Speed: Adjusting Cylinder Retraction Speed: 3-20 KVAL 990-H Service Manual...
  • Page 65 2-15 daily control power light six month description 3-15 weekly doorstops network system setting up 2-19 overview drill bit nodes replacing 2-13 back section dura-lith grease, bearing lube frame connections high frequency inputs outputs KVAL 990-H Operation Manual...
  • Page 66 2-14 product return procedure zero-energy start-up 1-12 clean up 1-10 inspect 1-10 return material authorization (RMA) 1-12 returning the product to Kval 1-12 router bit replacing 2-13 safety guidelines Safety Sign Off Sheet Safety Concerns 1-14 screw driver node input output...

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