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Kval 990-HB Operation And Service Manual

Pre-hanging door system
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Innovation, Quality & Honesty
990-HB Pre-Hanging Door System
Operation and Service Manual
Published: 2/23/15

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Summary of Contents for Kval 990-HB

  • Page 1 Innovation, Quality & Honesty 990-HB Pre-Hanging Door System Operation and Service Manual Published: 2/23/15...
  • 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 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 you! http://www.kvalinc.com KVAL 990-HB Operation Manual...
  • Page 4 KVAL 990-HB Operation Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction to the 990-HB Door Hanging System Chapter 1 Chapter 1 at a Glance.............. 1-1 Overview of the 990-HB Door Hanging System ...... 1-2 About this Manual .................1-3 Safety First!................1-4 Safety Sheet Sign-Off Sheet..............1-4 Safety Terminology of Labels..............1-4 Safety Guidelines..................1-4...
  • Page 6 Calibration of 990-HB Chapter 3 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...
  • Page 7 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 Bits in the Front Section ............5-11...
  • Page 8 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 ................6-18 990-HB Door Hanging System...

  • Page 9: Chapter 1 At A Glance

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

  • Page 10: Overview Of The 990-Hb Door Hanging System

    Overview of the 990-HB Door Hanging System Overview of the 990-HB Door Hanging System The KVAL Model 990-HB door pre-hanging system combines very high quality hardware detail- ing, with high speed productivity. Unique features include: • Computer controlled ball screw movements for all routers and chisels, complete with square hinges and lock face plates.

  • Page 11: About This Manual

    Overview of the 990-HB Door Hanging System About this Manual This manual contains operation information 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.

  • Page 12: Safety First

    See “Safety Sign-Off Sheet” on page 1-16. Safety Terminology 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.

  • Page 13: Lockout Tagout Procedure

    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 1-8. KVAL 990-HB Operation / Service Manual...
  • Page 14 This should be done in accordance with applicable state and/ or federal code requirements. KVAL 990-HB Operation / Service Manual...
  • Page 15 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 16: Lockout Tagout Procedure

    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. KVAL 990-HB Operation / Service Manual...
  • Page 17 • 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-HB Operation / Service Manual...

  • Page 18: 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 1-10 KVAL 990-HB Operation / Service Manual...

  • Page 19: 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 20 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. 1-12 KVAL 990-HB Operation / Service Manual...

  • Page 21: 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 22 • 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 23 Getting Help from KVAL Page Intentionally Left Blank 1-15 KVAL 990-HB Operation / Service Manual...

  • Page 24: 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 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: Chapter 2 Operation Of The 990-Hb

    CHAPTER 2 Operation of the 990-HB This chapter describes components, assemblies, and the user interface of the KVAL 990-HB Door Hanging System. The content is geared to help operators understand the basic operation of the 990-HB. Included are instructions to calibrate the machine and run a door.

  • Page 28: Operator's Tour

    Operator’s Tour Operator’s Tour This section takes you on a tour of the 990-HB Pre-Hanging Door machine. The 990-HB cuts hinge pockets on both a door and a jamb and then attaches hinges to them. While the hinge process takes place, a door lock and face plate is drilled.

  • Page 29: About The 990-Hb

    • The door is automatically positioned while the operator loads and clamps the hinge jamb. Lock Back Section Operator Controls Feed System Hydraulic Tanks for Six Shooters Key Assemblies on the In-Feed Section FIGURE 2- 2. KVAL 990-HB Operation / Service Manual...

  • Page 30: Hinge Carriage

    Creates a clean cut router. with no chipping. Hinge Carriage Parts FIGURE 2- 3. KVAL 990-HB Operation / Service Manual...

  • Page 31: Six Shooter System

    'A' or 'B' series at the user station under the Main Screen. Six Shooter 3 Six Shooter 2 Six Shooter 1 Hopper A1 Hopper B1 Hopper A2 Hopper B2 Hopper A3 Hopper B3 Hopper Bank Designations FIGURE 2- 4. KVAL 990-HB Operation / Service Manual...
  • Page 32 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 Magnetized Screws in Hopper. Magnetized screws can cause sluggish response to screws getting stuck.
  • Page 33 Assembly cycle one more time to clear the screws from the slides. Press the button on the Six Shooter panel located mid machine on the front Reset section. Fill the Hopper with new screws. KVAL 990-HB Operation / Service Manual...

  • Page 34: About The Six Shooter Assembly

    Six Shooter Call-Outs FIGURE 2- 6. Driver Assembly The Driver Assembly is the work horse of the Six Shooter. The assembly automatically receives, aligns, and drives the screws into the door and the jamb. KVAL 990-HB Operation / Service Manual...
  • Page 35 Factory set to align hinge. Latch Arm: Latches to H Block Latch Arm Cylinder: to secure in place. Moves latch arm in and out of position Six Shooter and Gear Box Call-Outs FIGURE 2- 7. KVAL 990-HB Operation / Service Manual...
  • Page 36 Squares Edges of Lock Plate Right Lock Plate Chisel: Squares Left Lock Edges of Lock Plate Chisel Plate Lock Bore Limit Switches: Key Assemblies on the Back Section (Back View) FIGURE 2- 8. 2-10 KVAL 990-HB Operation / Service Manual...
  • Page 37 Chisel: Squares Edges of Edges of Lock Plate Lock Plate Back Sec- tion Chip Dust Collector Outs Path Lock Bore Router Motor Key Assemblies on the Back Section (Front View) FIGURE 2- 9. 2-11 KVAL 990-HB Operation / Service Manual...
  • Page 38 • The door is automatically positioned to be fed into the next machine Air Input System Bore Motor Valve Bank Dust Collection Blow -Off Nozzles Key Assemblies on the Out-Feed Section FIGURE 2- 10. 2-12 KVAL 990-HB Operation / Service Manual...

  • Page 39: About The Electrical Panels

    Operator’s Tour About the Electrical Panels The 990-HB has a Main Electrical Panel and a High Frequency Panel. Figure 2- 11 below, is an overview of the location of assemblies in the panels The High Frequency Panel The Main Electrical Panel: •...

  • Page 40: Description Of The Six Light Panel

    Operator’s Tour Description of the Six Light Panel The six lights on this panel indicate the status of the 990-HB system. The Sequence that the lights activate is as follows: Control Power Overload Relay E-Stop Stop Start 24VDC Stop – This light will Control Power –...

  • Page 41: About Sensors

    Operator’s Tour About Sensors On the 990-HB, sensors provide input to the PLC as part of the automation of the door cutting process. It is important to keep the sensors cleaned and aligned to keep the door process running smoothly. There are two classifications of sensors on the 990-HB------Photo Electronic and Inductive Proximity Sensor.

  • Page 42: About Motion Of Servo Motors: X,Y, Z, And W

    Red = Reverse Green= Open Green= Open Green= Down Green= Forward (width adjust) Z Axis W Axis Y Axis X Axis = Reverse Direction Green = Forward Direction Servo Drive Motions FIGURE 2- 13. 2-16 KVAL 990-HB Operation / Service Manual...

  • Page 43: Quick Start

    Quick Start Quick Start Ensure factory air is present at machine and the 990-HB main air supply valve is turned on. Power up the 990-HB.See “How to Power Up the 990-HB” on page 2-19. Home the 990-HB. See “Home the 990-HB” on page 2-20.
  • Page 44 When the process is completed the door will feed out and a new door will feed in To continue processing another door go to step 7. 2-18 KVAL 990-HB Operation / Service Manual...

  • Page 45: Powering Operations For The 990-Hb

    Powering Operations for the 990-HB Powering Operations for the 990-HB This section describes how to power up and to power down the 990-HB. Powering up the system includes: • Applying power to the entire system • Starting the Control Circuit Powering down the system includes: •...

  • Page 46: Home The 990-Hb

    The 990-HB must go through a homing routine before any operations are performed. The homing routine sets a zero reference from which the 990-HB measures its movement and cutting process. If power is lost or the 990-HB is re-set, the homing routine must be performed again to reset the zero reference...

  • Page 47: Emergency Shutdown And Recovery

    990-HB. During normal operation, remove each of the three red safety hooks from the Six-Shooter heads and place in the hanging storage spot above the in-feed end of the 990-HB. 2-21 KVAL 990-HB Operation / Service Manual...

  • Page 48: Description Of User Interface Screens

    This section describes the user interface screens. The user interface allows the operator to use a touch screen to control the door cutting process, auto-run, manually 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.

  • Page 49: Machine Feed Back

    Note: Use this information to isolate issues if having problems with the machine. Controlling Access to User Screens The 990-HB has the ability to lock out changes to certain parameters such a presets and calibra- tions. Locked out parameters may vary due to customer design wants.

  • Page 50: Main Screen

    Description of User Interface Screens 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. Main Screen FIGURE 2- 14. 2-24 KVAL 990-HB Operation / Service Manual...
  • Page 51 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.
  • Page 52 • The choice of pre-drill patterns You can select buttons to down load pre-drill parameters or turn off this func- Pre-Drill tion. To set Pre-Drill parameters, see “About the Pre-Drill Screen” on page 2-32 . 2-26 KVAL 990-HB Operation / Service Manual...
  • Page 53 Clear Screws Button allows you to clear any stuck screws in the six Clear Screws shooter heads. 2-27 KVAL 990-HB Operation / Service Manual...

  • Page 54: About The Setup Screens

    Setup Menu FIGURE 2- 15. 2-28 KVAL 990-HB Operation / Service Manual...
  • Page 55 Jamb Shelf Height Adjustments Adjusts the jamb shelf height. This parameter is usu- ally set once. Lock Bore Location Adjustments This menu adjusts the Lock Bore Location on the edge of the door. 2-29 KVAL 990-HB Operation / Service Manual...

  • Page 56: About The Setup Hinges 1-3 Screens

    Hinge Setup Menu (1 of 3) FIGURE 2- 16. 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. 2-30 KVAL 990-HB Operation / Service Manual...
  • Page 57 X, Y, and Z direction. Lower Right Chisel (X, X,Y,and Z): Adjustments here moves just the lower right chisel in the X, Y, and Z direction. 2-31 KVAL 990-HB Operation / Service Manual...

  • Page 58: About The Pre-Drill Screen

    Delrin. Mirror Image of Jamb Parameters Entered Positive Door Direction 'Y' Zero Point Positive Direction Negative Direction 'X' Zero Point Pre-Drill Screen Description FIGURE 2- 17. 2-32 KVAL 990-HB Operation / Service Manual...

  • Page 59: About The Lock Plate Screen

    Lock Carriage 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. Lock Plate Screen FIGURE 2- 18.
  • Page 60 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 information. 2-34 KVAL 990-HB Operation / Service Manual...

  • Page 61: About Manual Operation

    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. Manual Operation Screen FIGURE 2- 19. 2-35 KVAL 990-HB Operation / Service Manual...
  • Page 62 Test Mode runs the hinge cycle, but does not extend the tools. This is primarily used to verify a new template is correct and the hinge carriage will not bump into the H-Block or other assemblies. 2-36 KVAL 990-HB Operation / Service Manual...
  • Page 63 Select the white box and enter the speed of the car- Speed: riage. The range is 1% to 100%. Use the number pad to enter the desired speed and press OK when finished. 2-37 KVAL 990-HB Operation / Service Manual...
  • Page 64 Exit Application Press the button to close the user screen and Exit Application return to the Windows desktop. This can be used if the opera- tor needs to use a different Windows application. 2-38 KVAL 990-HB Operation / Service Manual...

  • Page 65: Diagnostic Screen

    The top line will have the most current routine that is running. If the machine issue can not be resolved, call KVAL Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the KVAL representative.
  • Page 66 Diagnostic Screen 2-40 KVAL 990-HB Operation / Service Manual...

  • Page 67: Chapter 3 Calibration Of 990-Hb

    CHAPTER 3 Calibration of 990-HB This chapter describes the steps to calibrate the 990-HB, Door Pre-Hanging Machine Chapter 3 at a Glance About Calibration .................... 3-2 Before you Calibrate .................. 3-2 Flow Chart of Calibration ................. 3-3 About the KVAL Calibration Routine .............

  • Page 68: About Calibration

    The KVAL 990-HB has a built in Calibration routine to cut a horizontal slot with known parame- ters. The routine allows you to make the cut, measure, observe any anomalies, and help isolate to the component that causes the problem.

  • Page 69: Flow Chart Of Calibration

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

  • Page 70: About The Kval Calibration Routine

    The front end assemblies that use the calibration routine are as follows: Hinge Carriage Router Counter Rotate Router Chisels Pre-Drill Router Counter Rotate Router Pre-Drill Chisels Hinge Carriage Location of Assemblies FIGURE3- 2. KVAL 990-HB Operation / Service Manual...

  • Page 71: Calibration Slot Drilling Specifications

    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'' KVAL 990-HB Operation / Service Manual...

  • Page 72: Run The Calibration Routine

    Choose door Length. Disable three of the hinges leaving one hinge enabled. Load the Door and Start the Cut Load the test door into the in-feed of the 990-HB. Verify the setup and check for machine is safe to run. Press the button, to begin the process.

  • Page 73: Check Specifications Of The Front Section

    Sample of Adjustment Menu FIGURE3- 5. Note: KVAL suggests to follow the steps in the order below. Step 1 Verify and Adjust the Hinge Carriage Step 2 Verify and Adjust the Router Calibration Step 3 Verify and Adjust the Pre-Drill Calibration...

  • Page 74: Step 1: Hinge Carriage Calibration

    Exit out of the Setup screen and rerun the Calibration test. Re-measure the slot. If slot is not centered, repeat the steps above until the slot is centered. After centering is achieved, select to store the corrections. Combine with Base KVAL 990-HB Operation / Service Manual...
  • Page 75 Enter the offset in this box. Select the check mark to confirm this number and exit to go back to the Setup screen. Exit out of the Setup screen and rerun the Calibration test. Re-measure the parameters of slot. KVAL 990-HB Operation / Service Manual...

  • Page 76: Step 2: Router Calibration

    • The width should = the diameter of the bit. • The slot should be centered in the H-block and center on the thickness of the door. Adjusting the Router: Run the Calibration Routine. See “Run the Calibration Routine” on page 3-6. 3-10 KVAL 990-HB Operation / Service Manual...

  • Page 77: Step 3: Counter Rotate Router Calibration

    Follow the procedures to calibrate as described in the “General Instructions to Adjust X, Y, and Z” section, except apply the calculations and inputs to the Counter Rotate Router menu. Below is a summary of the calibration steps 3-11 KVAL 990-HB Operation / Service Manual...

  • Page 78: Step 4: Pre-Drill Calibration

    Run the Calibration Routine. See “Run the Calibration Routine” on page 3-6. Check, measure, and calculate specifications of Pre-Drill cut. To set a new reference, go to the calibration menu and select Combine with Base Enter calculations. 3-12 KVAL 990-HB Operation / Service Manual...

  • Page 79: Step 5: Chisel Calibration

    After the hinge run is finished, check all four corners of the hinge to see if the chis- els are in the correct location. If the corners of the hinge are out of specification, continue the process on the next page. 3-13 KVAL 990-HB Operation / Service Manual...
  • Page 80 Select the button to combine the two numbers to create refer- Combine with Base ence. 3-14 KVAL 990-HB Operation / Service Manual...

  • Page 81: Calibration Of The Back Section

    Calibration of the Back Section Calibration of the Back Section For the 990-HB, there are two screens available to calibrate the back section. From the select --> to get to the Machine Calibration screen to access: Main Screen Setup Main Cal •...

  • Page 82: Lock Location Calibration

    Measure again and repeat steps 3 to 4 until the center of the lock is at the desired cut location. Once the completed with calibration, select the Combine button to store the data. with Base Exit Main Calibration Screen. 3-16 KVAL 990-HB Operation / Service Manual...

  • Page 83: Lock Bore Calibration

    Measure again and repeat steps 3 to 4 until the center of the lock bore is at the desired cut location. Once the completed with calibration, select the button to Combine with Base store the data. Exit Main Calibration Screen. 3-17 KVAL 990-HB Operation / Service Manual...
  • Page 84 Calibration of the Back Section 3-18 KVAL 990-HB Operation / Service Manual...

  • Page 85: Chapter 4 System It Administration

    CHAPTER 4 System IT Administration This chapter describes the KVAL 990-HB controller. The controller is an on board computer that supplies the user interface and controls the operation of the machine. With the controller, KVAL can remotely help troubleshoot your machine.
  • Page 86 Support will be able to access your machine through your company’s Intranet and help solve any issues that may occur. Connection to the Intranet is achieved by interfacing with the 990-HB con- troller. The location of the Intranet connection is identified in the figure below (RJ45 to Intranet.) About the 990-HB Computer ®...

  • Page 87: About Remote Connection To Kval Service

    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 ®...
  • Page 88 System IT Administration KVAL 990-HB Operation / Service Manual...

  • Page 89: Chapter 5Maintenance Of The 990-Hb

    CHAPTER 5Maintenance of the 990-HB This chapter describes preventative maintenance steps for KVAL 990-HB. 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 90: 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 5-1. Type of Assembly Recommended Schedule Recommended Lubrication Type Linear Bearing...

  • Page 91: Six Month Checkups

    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 92: 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 93: 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 94: 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-HB Operation / Service Manual...

  • Page 95: Lubrication Points On The 990-Hb

    Lubrication Points on the 990-HB 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 Feed System Lubrication Points FIGURE5- 16. KVAL 990-HB Operation / Service Manual...

  • Page 96: Screw Driver

    Lubrication Points on the 990-HB Screw Driver Screw Drive Lubrication Points FIGURE5- 17. KVAL 990-HB Operation / Service Manual...

  • Page 97: Back Section

    Lubrication Points on the 990-HB Back Section Back View Front View Back View 2 Bottom View FIGURE5- 18. KVAL 990-HB Operation / Service Manual...
  • Page 98 Lubrication Points on the 990-HB Heads Bottom Back 1.Assemblies shown transparent. FIGURE5- 19. 5-10 KVAL 990-HB Operation / Service Manual...

  • Page 99: Replacing Bits

    Replacing Bits Replacing Bits The 990-HB is a powerful electro-mechanical motion Caution control system. If servicing the 990-HB 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 100: 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. FIGURE5- 21. Inspect and clean collet assembly. 5-12 KVAL 990-HB Operation / Service Manual...
  • Page 101 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 FIGURE5- 23. Tighten the collet assembly. 5-13 KVAL 990-HB Operation / Service Manual...

  • Page 102: 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. 5-14 KVAL 990-HB Operation / Service Manual...
  • Page 103 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 5-15 KVAL 990-HB Operation / Service Manual...

  • Page 104: Mechanical Set Up Of The 990-Hb

    Note: Mechanical set up was made at the factory and little if any adjustments should be made at initial setup. This section describes the method to mechanically set the references for the front section and back section of the 990-HB. Adjustment descriptions include: Back Section Front Section •...

  • Page 105: Back Section

    Mechanical set up of the 990-HB Setting Up the Hinge Backset The hinge backset on the 990-HB is controlled by two positive stop bolts on each of the three routing carriages. • To adjust loosen the lock nut and adjust the bolt accordingly to give the right hinge backset.
  • Page 106 Mechanical set up of the 990-HB Turn on the control transformer and press the start machine button, push the start sequence button at the operators panel Lock bore and router should come up at the same time, and move through their respective motions Lock bore lowers and router shifts out.
  • Page 107 If for some reason the faceplate is not centered on the latch hole, you can adjust the screws that contact the turret bolts. If both the plate and latch hole are off-center, contact KVAL for instruc- 5-19...
  • Page 108 Mechanical set up of the 990-HB tions on shimming the self-centering clamp system. The turret bolts should never be adjusted, since these were micrometer-set at the factory. Note: 5-20 KVAL 990-HB Operation / Service Manual...

  • Page 109: Chapter 6 Troubleshooting The 990-Hb

    Troubleshooting the 990-HB 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 6 at a Glance About Sensors ....................

  • Page 110: About Sensors

    About Sensors About Sensors On the 990-HB, sensors provide input to the PLC as part of the automation of the door cutting process. It is important to keep the sensors cleaned and aligned to keep the door process running smoothly. There are two classifications of sensors on the 990-HB------Photo Electronic and Inductive Proximity Sensor.

  • Page 111: Location Of Sensors On 990-Hb

    About Sensors Location of Sensors on 990-HB Figure 6- 26 below, shows the sensor locations on the 990-HB The “I” designation represents an input to the PLC and the “Q” designation represents an output from the PLC. Door Sense Eye...

  • Page 112: Z Axis And Y Axis Front Section Sensors

    Z-Axis Forward Crash Eye Hinge #3 Hinge #1 Hinge #2 Y-Axis Home Eye Y-Axis Reverse Crash Eye Y-Axis Forward Crash Eye Figure 6- 27 Section View of 990-HB Y Axis and Z-Axis Sensors FIGURE 6- 27. KVAL 990-HB Operation / Service Manual...

  • Page 113: Axis Sensors Front Section

    The sensors are located underneath the Heads. X-Axis Home Eye X-Axis Reverse Crash Eye X-Axis Forward Crash Eye Hinge #3 Hinge #2 Hinge #1 Bottom View of 990-HB location of X Axis Sensors FIGURE 6- 28. KVAL 990-HB Operation / Service Manual...

  • Page 114: Troubleshooting Electrical Problems

    Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Panel. If copies NOTE: 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 115: Error Checking On The Variable Frequency Drives

    The Status Light Panel is located on the Electrical Panel. All six lights are illuminated when the system is in proper working order. The lights turn on in a sequence and will stop at the point where a fault is first detected. KVAL 990-HB Operation / Service Manual...
  • Page 116 STEP 4: Stop (Amber) If light is OFF go to item on page 6-10. STEP 5: Start (Amber) If light is OFF go to item on page 6-11. STEP 6: 24VDC (Green light is OFF go to item on page 6-11. KVAL 990-HB Operation / Service Manual...
  • Page 117 If no power on the output side, and there is power going into the top of the Control Transformer, replace the Control Transformer. If 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. KVAL 990-HB Operation / Service Manual...
  • Page 118 Stop button to make sure it is all the way out and not stuck in, then check the contact to make sure it is closed. If still no voltage, check the wiring. 6-10 KVAL 990-HB Operation / Service Manual...
  • Page 119 Reinstall the (+ 24V positive) wires one by one, checking for +24VDC after installing each. If at any point no voltage is found trace the last reinstalled wire and check for shorts. 6-11 KVAL 990-HB Operation / Service Manual...

  • Page 120: 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. 6-12 KVAL 990-HB Operation / Service Manual...

  • Page 121: Adjusting Cylinder Extension Speed

    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 122: Network System Overview

    Network System Overview Network System Overview A PLC controls the 990-HB. The 990-HB PLC can process multiple analog and digital inputs, and output arrangements. The system can handle extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.

  • Page 123: Connections To Servo Drives

    Servo Drive 3 Servo Drive 6 2 High Voltage Outputs 2 High Voltage Outputs Servo Drive 2 2 High Voltage Outputs Servo Drive 4 2 High Voltage Outputs Servo Drives FIGURE 6- 30. 6-15 KVAL 990-HB Operation / Service Manual...

  • Page 124: High Frequency Panel Node Connections

    For detailed wiring information, see your machine’s electrical drawings. Outputs Inputs Ether CAT Input (From Frame Node) Ether CAT Output (To E-Stop Circuitry) Coupler PLC Interface High Frequency Node Sample FIGURE 6- 31. 6-16 KVAL 990-HB Operation / Service Manual...

  • Page 125: Frame, Screw Driver, And Back Section Node Locations

    • Six shooter inputs and outputs, • Hopper inputs and outputs, • Screw driver related inputs and outputs. For detailed wiring information, see your machine's electrical drawings. 6-17 KVAL 990-HB Operation / Service Manual...

  • Page 126: Back Section Node

    Back Section 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. 6-18 KVAL 990-HB Operation / Service Manual...
  • Page 127 2-39 readout description door spec group Beckhoff® CPU module description 2-26 bit assemblies drill bit how to access 5-12 replacing 5-11 bits dura-lith grease, bearing lube replacing 5-11 DVI/USB module location calibration electrical panels KVAL 990-HB Operation / Service Manual...
  • Page 128 2-30 2-23 hinge spec group servo positons 2-23 description machine status 2-26 home button general feedback 2-23 description user interface main cal screen 2-25 using group locations 2-20 2-28 main electrical panel KVAL 990-HB Operation / Service Manual...
  • Page 129 1-16 connections screw driver node location input output 6-17 location in main electrical panel screwdriver bits 2-13 power remove and replace 5-14 disconnect switches sensors lock out procedure descriptions power up location on frame KVAL 990-HB Operation / Service Manual...
  • Page 130 1-11 stop sequence button inspect 1-11 description user interface 2-25 strike plate calibration 3-17 strike plate location adjusting 3-17 tagout procedure troubleshooting air cylinders 6-12 using status lights TwinCAT 2® software automation software KVAL 990-HB Operation / Service Manual...

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