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Kval 990-HQ Operation Manual

Pre-hanging door system
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Operation Manual
Published:August 15, 2019
Innovation, Quality & Honesty
990-HQ Pre-Hanging Door System

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Summary of Contents for Kval 990-HQ

  • Page 1 Operation Manual Published:August 15, 2019 Innovation, Quality & Honesty 990-HQ Pre-Hanging Door System...
  • 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-HQ Operation 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-HQ Operation Manual...

  • Page 5: Table Of Contents

    Safety Sign-Off Sheet .............. 1-19 A Note to the Operator................1-19 Operation of the 990-HQ Chapter 2 The 990-HQ Process Summary..........2-2 Machine Orientation................2-2 Typical Production Line Layout.............2-2 Top View of Machine..............2-3 About the Operator Station and Front Section Controls ..2-4 About the Foot Pedal and Control Box ..........2-5...
  • Page 6 Description of the Six Light Panel ........... 2-20 Machine Start Summary ............2-21 If Processing a Fourth Hinge ..............2-23 Powering Operations for the 990-HQ ........2-24 How to Power Up the 990-HQ ............2-24 Home the 990-HQ................2-25 How to Power Down the 990-HQ............2-25 Safety Controls ................
  • Page 7 Screen Details ..................2-50 Chisel Calibration..............2-54 About the Pre-Drill Screen ............2-55 Entering Pre-Drill Pattern Data ............2-55 Example of Data Input ................2-56 Diagnostic Screen..............2-57 Status of I/O and E-Stops Screen ..........2-58 Appendix: Machine Component Terms........2-60 KVAL 990-HQ Operation Manual...
  • Page 8 Table of Contents KVAL 990-HQ Operation Manual...

  • Page 9: Chapter 1 At A Glance

    Chapter 1 at a Glance Section Name Summary Page This section provides an overview of the 990-HQ. It page 1-2 Overview of the includes a general description and a table of available System...

  • Page 10: About This Manual

    About this Manual About this Manual The 990-HQ entry door pre-hanging system produces machined doors with one or two cylindrical locks and either three or four hinges attached to the door edge and hinge jamb. Hinges can be mounted with or without hinge pins inserted.
  • Page 11 The Touch Screen logic also includes management functions such as Daily and Lifetime Totals. When connected to the internet, the PC allows remote support and monitoring of machine functions from Kval in Petaluma, CA. Door and jamb clamp reference: The door will clamp downwards rather than upwards and the jamb reference will be to jamb stop (top of H block not staging block for jamb edge).
  • Page 12 Service Manual Chapter Title Description Chapter 1 System IT Brief description of Computer and PLC in the Machine Chapter 2 Maintenance Maintenance steps for the machine line Chapter 3 Trouble Shooting Troubleshooting tips and theory of opera- tion. 990-HQ Operation Manual...

  • Page 13: Safety First

    See “Safety Sign-Off Sheet” on page 1-19. 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 14 All cylinders on machine are under high pressure and can be very dangerous when activated. 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 1-10. 990-HQ Operation Manual...
  • Page 15 This should be done in accordance with applicable state and/or federal code requirements. Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions. 990-HQ Operation Manual...
  • Page 16 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 17: Lockout-Tagout Guidelines

    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 990-HQ Operation Manual...

  • Page 18: Lockout Tagout Procedure

    Turn Switch to the Lock and Tag out Insert Lock into hole. OFF position Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided. 990-HQ Operation Manual 1-10...

  • Page 19: Lockout Tagout Air Supply

    The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized. The tags must be destroyed and the locks and keys returned to the lockout center. 990-HQ Operation Manual 1-11...

  • Page 20: 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 “Getting Help from KVAL” on page 1-14. Check Controls Confirm that all switches are in the “OFF”...
  • Page 21 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. 990-HQ Operation Manual 1-13...

  • Page 22: Getting Help From Kval

    Ask about this procedure when calling are service team Product Return Procedure If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure below to return the machine or part.
  • Page 23 • 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 24: How To Download The Service Application

    Download Application To download the application, go the KVAL website ( http:// www.kvalinc.com At the KVAL website, select the tab. Follow the instruc- Support tions on the Support web page. Click the Download button to download the application that...
  • Page 25 Session code: An internal number to track this machine. It is auto filled. Your Name Field: Enter your name. The KVAL techni- cian will use this field to identify this machine. Description: Enter machine Serial number and issue.
  • Page 26 How to Download the Service Application Page Intentionally Left Blank 990-HQ Operation Manual 1-18...

  • Page 27: Safety Sign-Off Sheet

    Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the KVAL website (http:// www.kvalinc.com). You may also contact our Service Department at (800) 553- 5825 or email at service@kvalinc.com.
  • Page 28 Safety Sign-Off Sheet 990-HQ Operation Manual 1-20...
  • Page 29 Operation of the 990-HQ CHAPTER 2 This chapter describes components, assemblies, and the user interface of the KVAL 990-HQ Door The content is geared to help operators understand the basic operation of the Hanging System. machine. Included are instructions to calibrate the machine and run a door.

  • Page 30: The 990-Hq Process Summary

    This manual assumes 990-HQ as a feeder. The feeder is addressed in a separate manual. ON-12HQ 990-HQ Door Hanger ON-12HQ Feeder The 990-HQ Door Hanging System FIGURE2- 1. 990-HQ Operation Manual...

  • Page 31: Top View Of Machine

    • Drill(x2) ( Drills lock hole on screws) the face of the door) • Screw Driver Note: the 990-HQ can rout 4 hinge pock- ets with 3 Carriage Heads. .Top View of 990-HQ Pre-Hanging Door Machine FIGURE2- 2. 990-HQ Operation Manual...

  • Page 32: About The Operator Station And Front Section Controls

    Stops the Machine Process Store Program: To allow the operator to Emergency Stop: make changes to param- eters, turn the Set Up Stops machine in an Lock to the On position emergency situation. Operator Station FIGURE2- 3. 990-HQ Operation Manual...

  • Page 33: About The Foot Pedal And Control Box

    Jamb Clamp Pedal:The jamb clamp pedal activates the jamb clamps to clamp the jamb in place. or to unclamp a jamb. Press once to clamp, press again to unclamp. See “Powering Operations for the 990-HQ” on page 2-24. Door Clamp / Un-Clamp Jamb Clamp / Un-Clamp...

  • Page 34: Hinges Loaded Button (Status Light)

    Eight-Shooter heads have begun to move into hinge application posi- tion. This button informs the Eight-Shooters that the hinges are loaded and ready to be applied Note: Once the is selected, do not enter Hinge Loaded Button the machine’s active area. 990-HQ Operation Manual...

  • Page 35: About The In-Feed Section

    Hydraulic Tanks for auto adjusts to in-fed Eight Shooters: Sup- door. Clamps and then plies pressurized fluid sends door through for operation of the machine for processing. Eight Shooters. Key Assemblies on the In-Feed Section FIGURE2- 4. 990-HQ Operation Manual...

  • Page 36: About The Front Section

    Location Servo tion and Front Section hinge pockets. A fourth Motor (X2). Controls” on page 2-4. hinge pocket can be cut if desired (H1 or H3) Key Assemblies on the Front Section FIGURE2- 5. 990-HQ Operation Manual...

  • Page 37: About The Hinge Heads

    See “Connections to Servo Drives” on page 6-30. This section supplies more information about the servo drives Key Assemblies on Heads FIGURE2- 6. 990-HQ Operation Manual...

  • Page 38: About The Eight Shooter System

    Any adjustment may cause timing issues with the operation of the Eight Shooter. If you think problems are being caused by the cylin- ders, please contact the KVAL Service Department for direction. Important: Do not mix screw types in the Hopper. Different sizes, pitches can cause uneven application of the hinge.

  • Page 39: Hopper Process

    Hopper Hopper Cyl- to organize the screws and deliver them to the inders Screw Tracking Plate monitors the quantity of screws delivered to the to the Gate Assembly Screw Tracking Plate Assembly. 990-HQ Operation Manual 2-11...
  • Page 40 ) moves upward to drain the rest of the screws out of the hopper this will Assembly cycle one more time to clear the screws from the slides. Press the button to fill the Hopper with new screws. Load Hoppers Button 990-HQ Operation Manual 2-12...

  • Page 41: About The 8 Shooter Assembly

    Drives screw driver assembly See “About the Driver Assembly” on page 2- Tubes: Hinge Application: Delivers Screws to Hinge Applicator by way of plastic See “About the Driver tubes. Assembly” on page 2-14 Eight Shooter Call-Outs FIGURE 4. 990-HQ Operation Manual 2-13...

  • Page 42: About The Driver Assembly

    Magnets (x4): Magnets hold Hinge for Application. Latch Arm Cylinder: Latch Arm: Moves latch arm in and out Latches to H Block to secure in place. of position Eight Shooter and Gear Box Call-Outs FIGURE 5. 990-HQ Operation Manual 2-14...

  • Page 43: About The Back Section

    • Includes a top lock and a bottom lock drill to drill the face of the two. The two drills eliminates chip out. Back Section: See “Front and Rear Views of the Back Section” on page 2-16 Key Assemblies on the Back Section FIGURE2- 1. 990-HQ Operation Manual 2-15...

  • Page 44: Front And Rear Views Of The Back Section

    Bolt on the Oil Reservoir side of the door Servo Motor Edge Clamp (X2): Clamps edge of door Oil Reservoir Face Plate Motor and Drill: Lock Bore Limit Switch Routs face plate. Lock Bore Extend and Retract Cylinder 990-HQ Operation Manual 2-16...

  • Page 45: About The Out-Feed

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

  • Page 46: About The Electrical Panels

    Terminals 110 V / 24 V Terminals High Voltage Section High Voltage Section Input / Output Terminals Input / Output Terminals Servo Drives VFD Section Overview of Main Electrical Panel and High Frequency Panel FIGURE2- 3. 990-HQ Operation Manual 2-18...

  • Page 47: Electrical Panel Option: Servo Box 2

    Servo Box 2 houses the servos for the Programmable Hinge Locations, Door Index, and Hinge Applicator Position. PLC and Power 110 V / 24 V Supplies Terminals High Voltage Sec- tion Input / Output Terminals Servo Drives 990-HQ Operation Manual 2-19...

  • Page 48: Description Of The Six Light Panel

    Description of the Six Light Panel The six lights on this panel indicate the status of the Architect-DI system. The Sequence that the lights activate is as follows: Control Power Overload Relay E-Stop Stop Start 24VDC 990-HQ Operation Manual 2-20...

  • Page 49: Machine Start Summary

    . For a full description 990-HQ of power up and power down of the machine,see “Powering Operations for the 990-HQ” on page 2-24. Ensure factory air is present at machine line. Make sure the doors are stacked in loading area of Feeder. and machine process area is clear and ready for work.
  • Page 50 Home these steps. 1. Load the jamb on top of ledge pressing tightly against fence. 2. After Jamb is secure, press the Jamb to clamp the Jamb. Clamp Foot Pedal 990-HQ Operation Manual 2-22...

  • Page 51: If Processing A Fourth Hinge

    After the position is set, repeat the process starting from Start Sequence. 1. Start Sequence 2. Load Hinge a.Right hand doors use 8 Shooter #1. b.Left hand doors use 8 shooter # 3. Select the Hinge Loaded Button Process a door. 990-HQ Operation Manual 2-23...

  • Page 52: Powering Operations For The 990-Hq

    • Shutting down the control power • Removing power from the entire system How to Power Up the 990-HQ Ensure factory air is applied to machine and main air supply is turned on. Make sure all E-Stop buttons are out.

  • Page 53: Home The 990-Hq

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

  • Page 54: Safety Controls

    Air Brake on 990-HQ Eight Shooter The 990-HQ has air brakes on the Eight Shooter assemblies. The brakes will lock the 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.
  • Page 55 Once the screw drivers start dropping down and the Scanner field is broken, the machine the ver- tical breaks will be applied. The machine will have to be reset and re-homed. 990-HQ Operation Manual 2-27...

  • Page 56: Summary Of The Interface

    Below are screen shots of the operator screens that control the machine. Main Control is also the startup screen for the Main Screen 990-HQ. From this screen, all the basic user inter- face controls are available to run a door. See “Main Screen” on page 2-31. Manual Servo Control...
  • Page 57 Summary of the Interface Diagnostic Screen displays the all the tasks the Diagnostic Screen 990-HQ performs. This screen can help with trouble shooting by associating the error code to machine sec- tions or functions See “Diagnostic Screen” on page 2-57.

  • Page 58: Machine Feed Back

    Controlling Access to User Screens The 990-HQ has the ability to lock out changes to certain parameters such a presets and calibra- tions. To allow the operator to make changes to parameters, turn the Set Up Lock to the On position.

  • Page 59: Main Screen

    Main Screen Main Screen The Main Screen is also the startup screen for the 990-HQ. From this screen, all the basic user interface controls are available to run a door. Main Screen Descriptions Main Screen FIGURE2- 4. 990-HQ Operation Manual...
  • Page 60 Press this button to shut down the computer. Use this button as part Shut Down System: of the normal shutdown process. See “How to Power Down the 990-HQ” on page 2-25. Preset Selection Button Group Pressing a preset button, calls one of twelve presets stored in memory.
  • Page 61 Displays depth (Z axis) of the Depth: hinge pocket. Displays the rounded corners Radius: of the hinge pocket. The Reveal is set by the 8 Shooter Pins and the H-Block Spacers. Reveal: Radius Overall Height Reveal Backset Length 990-HQ Operation Manual 2-33...
  • Page 62 See below of location to put the spacers and pins on the machine. See figure below for locations to install spacers and pins. Fourth Hinge Top Down Insert Spacers On Each H-Bock Center Hinge Top Down Insert Pins into each 8 Shooter 990-HQ Operation Manual 2-34...
  • Page 63 Unclamping on or off. The Auto Unclamping: Auto Unclamping auto unclamp button sets the machine to automatically unclamp the door after machin- ing is completed. For manual operation, see “Width Adjust Group” on page 2-38. 990-HQ Operation Manual 2-35...

  • Page 64: Manual Operation

    From this screen you can control certain functions of the machine in manual mode. From this menu branch, select to assemblies to move “jog” manually. Select the button to access these menus. When first pressed, the Manual screen will open the screen Manual Jog Manual Jog Screen Manual Screen FIGURE2- 5. 990-HQ Operation Manual 2-36...
  • Page 65 To stop, release the button. Select the white box and enter the speed of the carriage. The range is 1% to Speed: 100%. Use the number pad to enter the desired speed and press OK when finished. 990-HQ Operation Manual 2-37...
  • Page 66 Normal Speed: Normal Speed previous speed, release the button. Toggle Buttons: The buttons to the right toggle auto functions on or off. For descriptions of these but- tons, see “Auto Enable and Disable Buttons” on page 2-35. 990-HQ Operation Manual 2-38...
  • Page 67 In this group, the Hoppers can be controlled manually. Hoppers can be toggled on or off Can clear the screws in the hopper system Control the air supply to the hoppers Enable or disable screw drop Move Heads into position 990-HQ Operation Manual 2-39...

  • Page 68: About Calibration

    Check back side of th H-Blocks for sawdust build-up, which may affect depth. Note: KVAL recommends that a test door is run first and checked for specifications before a full run is started.If any cut parameters are inaccurate, use the embedded calibration routine as a step to verify the validity of the test setup.

  • 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-H. Calibration Process Flowchart FIGURE 2- 6. 990-HQ Operation Manual 2-41...

  • Page 70: About The Entering Data Into The Setup Screens

    Perform a visual check of the assem- bly to be calibrated and check the for error reporting. Finding Diagnostic Screen errors from these screens will help localize problem areas. 990-HQ Operation Manual 2-42...

  • Page 71: Enter A Positive Or Negative Number

    ‘Z” axis, the thumb represents the positive direction of the ‘Y” axis, then second finger represents the positive the direction of the ‘X’ axis. Either Front Section or Back Section Cuts Y Axis Positive movement Z Axis Positive movement X Axis Positive movement 990-HQ Operation Manual 2-43...

  • Page 72: Servo Motor Drive Assembly Locations

    Screw Shift 2 and 3 Servo Motors Screw Shift 1 Servo Motors Door/Jamb Stop Servo Motors Hinge Shift 1 Servo Motors Hinge Shift 3 Servo Motor Carriage Servo Motors Offset Offset Offset Offset Z: - Offset Offset 990-HQ Operation Manual 2-44...

  • Page 73: Setup Screen

    990-HQ Press the buttons to access this screen. Tune the assem- Setup and Main Cal blies on this screen by entering and storing offsets to bring into reference. Main Calibration Screen Descriptions Setup Menu FIGURE2- 7. 990-HQ Operation Manual 2-45...
  • Page 74 “Fast Plate” or “Slow Plate” mode. Disable the Single Step Disable/Enable Button: button to use the three stages. Single Step Enable the button to by pass the Single Step three stages and perform the bore with one sin- gle cut. 990-HQ Operation Manual 2-46...
  • Page 75 See “How to Enter Calibration Data” on page 2-42, for instructions to enter calibration data. The Screw Shift Offset should be calibrated from the inside out. Calibrate the S2/S3 offsets first, S3 next, and finally S1. Offset Offset Offset Offset 990-HQ Operation Manual 2-47...
  • Page 76 Right Hand Doors. The Right Hand Stops are located on the In-feed, while the Left Hand Stops are located at the Out-feed. This calibration tunes the servo motors for the Hinge locations of Head #1 and Head #3. Offset Offset Offset Offset 990-HQ Operation Manual 2-48...

  • Page 77: Setup Hinges 1-3 Screens

    This machine is equipped with a calibration routine that will Select the calibration routine from the to begin this Manual Screen calibration cut. Dimensions of a Calibration Cut Standard Router: Outer Lip Counter Rotate Router: Inner Cut Drill: Center 990-HQ Operation Manual 2-49...

  • Page 78: Screen Details

    Adjustments move the position of the Hinge Carriage Location: carriage (Pre-Drill, Router, and Chisels). Essentially this moves the all tool sets together as a unit up, down, across and into the jamb and the door. 990-HQ Operation Manual 2-50...
  • Page 79 This adjustment moves the pre-drills only, the chisels and the router will stay in the same position. Offset Offset Jamb Offset Door Offset Z: positive Offset plunges IN Z: negative Offset retracts Out 990-HQ Operation Manual 2-51...
  • Page 80 Z direction, as well as radius adjustments. This adjustment moves the router (pocket) only, the pre-drill and the chisels will stay in the same posi- tion. Offset Offset Offset Jamb Door Offset Z: positive Offset plunges IN Z: negative Offset retracts Out 990-HQ Operation Manual 2-52...
  • Page 81 Hinge 2 is not driven by a servo motor, but is driven pneumatically. For the Hinge 2 calibration, make mechanical adjustments and enter measurements calibration fields. Offset Offset Offset Offset Hinge 2 location. Non Servo driven 990-HQ Operation Manual 2-53...

  • Page 82: Chisel Calibration

    This adjustment moves the Chisels only, the pre-drill and the router will stay in the same position. Upper Upper Right Left Offset Jamb Offset Offset Door Off- Z: positive Offset plunges IN Z: negative Offset retracts Out Lower Lower Left Right 990-HQ Operation Manual 2-54...

  • Page 83: About The Pre-Drill Screen

    The jamb pre-drill holes are equal to the mirror image of the parameters entered. The number '0' entered in both X and Y are equal to no drill. Name the Template Enter Drill Hole Locations 990-HQ Operation Manual 2-55...

  • Page 84: Example Of Data Input

    Example of Data Input Important: Never enter a negative number in the 'Y' parameter. The pre-drill will try to drill off the door into the Delrin. 'Y' Zero 'X' Zero Point Point Pre-Drill Samples FIGURE 2-8. 990-HQ Operation Manual 2-56...

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

  • Page 86: Status Of I/O And E-Stops Screen

    • Red indicates the sensor is not active. Note: The illustrations in this section are designed to show the general location of the sensors. For detailed information correlate the machine ‘s electrical drawings to the sensor labels located on the machine. 990-HQ Operation Manual 2-58...
  • Page 87 Status of I/O and E-Stops Screen Safety Screen Displays real time feedback from the safety assemblies on the machine. Safety System: Feedback from PLC E-Stop: Verifies the activation and deac- tivation of all E-Stops 990-HQ Operation Manual 2-59...

  • Page 88: Appendix: Machine Component Terms

    The Six-Shooter is located at the left side of the machine.Six Shooters apply hinges and the secures them with screws. (3x3 pattern) Eight-Shooter The Eight -Shooter is located at the left side of the machine.Eight Shooters apply hinges and the secures them with screws. (4X4pattern) (Opt K) 990-HQ Operation Manual 2-60...
  • Page 89 Appendix: Machine Component Terms 990-HQ Operation Manual 2-61...
  • Page 90 43 user interface description 37 calibration description 40 entering data 42 flowchart 41 KVAL, getting help 14 steps before 40 control transformer switch power up 24 Left Hand Rule 43 lock access to user screens 30...
  • Page 92 Contacting KVAL Customer Service Phone and Fax: Mailing address: In the U.S and Canada, call (800) 553-5825 or fax Customer Support Department (707) 762-0485 Kval Incorporated Outside the U.S. and Canada, call (707) 762-7367 825 Petaluma Boulevard South or fax (707) 762-0485 Petaluma, CA 94952 Email: service@kvalinc.com...

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