Page 1 Innovation, Quality & Honesty 990-FX Pre-Hanging Door System Operation and Service Manual Published: 03/13/2018...
Page 2 This Manual is confidential and contains proprietary information and intellectual property of KVAL Inc., and i s 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-FX Operation/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-FX Operation/Service Manual...
Page 5: Table Of Contents
Table of Contents Introduction to the 990-FX Door Hanging System Chapter 1 Chapter 1 at a Glance.............. 1-1 Overview of the 990-FX Door Hanging System....... 1-2 Hopper Options..................1-2 Table of Available Options ..............1-3 About this Manual .................1-4 Safety First!................1-5 Safety Sheet Sign-Off Sheet..............1-5...
Page 6 Option Z: Screw Changing Hoppers ...........2-28 Description of the Six Light Panel .......... 2-29 Machine Start Summary ............2-30 Initial Powering Operations for the 990-FX Line ...... 2-33 How to Power Up the Line ..............2-33 Home the 990-FX ................2-34 How to Power Down the Machine............2-35 Emergency Shutdown and Recovery ..........2-35...
Page 7 System IT Administration............3-2 About the Machine Computer ...............3-2 Connections on the PLC...............3-2 Network Diagram ..................3-3 Backing up the Computer ..............3-3 About Remote Connection to KVAL Service.........3-4 Maintenance of the 990-FX Chapter 4 Maintenance Schedule ............4-2 300 Cycle Maintenance Steps ..........4-4 Clean, Clean, Clean!................4-4...
Page 8 About Taper Bearings .................4-21 Tapered Bearing Housings ..............4-21 Ball Screw Nut ..................4-22 Ball Screw Drive Assembly..............4-22 Pulley and Idler Shafts................4-23 Lubrication Points on the 990-FX ..........4-24 Back Section..................4-26 Heads ....................4-27 Servo Motor Assembly................4-28 Description of Air Input System ..........4-29...
Page 9 Replacing Tooling in the Back Section........4-35 Option SB (CNC Back Section) ............4-36 Changing the Bore Drill...............4-36 Changing the Bolt Drill ................4-37 Collet Torque Values..............4-38 Troubleshooting the 990-FX System Chapter 5 About Motion Control ............... 5-2 Basic Control Circuit ................5-2 Troubleshooting Basics ............5-4 Before you Adjust .................5-4...
Page 10 Using Sensors to Trouble Shoot ..........5-26 Using Sensors to Trouble Shoot ............5-26 Location of Sensors on 990-FX ............5-26 Z Axis and Y Axis Front Section Sensors ...........5-28 X Axis Sensors Front Section .............5-29 Network System Overview............5-30 Connections to Servo Drives ..............5-30 High Frequency Panel Node Connections..........5-31...
Page 11: Chapter 1 At A Glance
Chapter 1 at a Glance CHAPTER 1 Introduction to the 990-FX Door Hanging System This chapter provides an overview of the KVAL 990-FX Door Hanging System and important safety information to follow when operating the machine. Chapter 1 at a Glance Section Name...
Page 12: Overview Of The 990-Fx Door Hanging System
KVAL's 990-FX is the fastest and most productive pre-hanging system available in the industry. The 990-FX will rout a door and jamb for three or four hinges, drill pilot holes for the hinge screws, mortise for the lock, and apply three or (Opt four) hinges.
Page 13: Table Of Available Options
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.
Page 14: About This Manual
Overview of the 990-FX Door Hanging System About this Manual This manual is part of a package delivered with the machine line. includes the following: Operation/Service Manual Chapter Title Description Chapter 1 Introduction Descriptions of Machine Line and Safety Information.
Page 15: 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 16 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. KVAL 990-FX Operation/Service Manual...
Page 17 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. KVAL 990-FX Operation/Service Manual...
Page 18 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 19: 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 KVAL 990-FX Operation/Service Manual...
Page 20: 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. KVAL 990-FX Operation/Service Manual 1-10...
Page 21: 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. KVAL 990-FX Operation/Service Manual 1-11...
Page 22: 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 23 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. KVAL 990-FX Operation/Service Manual 1-13...
Page 24: 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 proce- dure below to return the machine or part.
Page 25 • 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 26: 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 27 Session code: An internal number to track this machine. It is auto filled. 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.
Page 28 How to Download the Service Application Page Intentionally Left Blank KVAL 990-FX Operation/Service Manual 1-18...
Page 29: 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 30 Safety Sign-Off Sheet KVAL 990-FX Operation/Service Manual 1-20...
Page 31 CHAPTER 2 Operation of the 990-FX This chapter describes components, assemblies, and the user interface of the KVAL 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...
Page 32: About The Machine Line
• The door 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 700-C, see...
Page 33: Assembly Identification On Machine
Back Section Six Shooter 3 Lock Bore Assembly Carriage Head 3 Carriage Head 2 Air Tank Front Section Six Shooter 2 Carriage Head 1 Six Shooter 1 Light Curtain Transmitte Electrical Panel # 1 In-Feed Operator’s Station KVAL Operation/Service Manual...
Page 34: Summary Of The Controls On The Machine Line
This section describes the controls located on the machine line. About the Operator Station Touch Screen Interface: Main Con- trol of the 990-FX. Auto load and run predetermined parameters on doors. Manually control the door path and process through the line. Machine...
Page 35: Descriptions Of Machine Controls
On position. When this key is in the Off position, the parameters are locked out. No changes to the parameters may be made in the off position. The key may be taken out in the off position, to prevent any inadvertent changes to the cut parameters. Set Up Lock KVAL Operation/Service Manual...
Page 36: Foot Pedal And Control Box
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 about the incoming door from the incoming machine.
Page 37: Hinges Loaded Button (Light Curtain Status Light)
Summary of the Controls on the Machine Line Hinges Loaded Button (Light Curtain Status Light) The 990-FX has at the front of the machine. Light Curtain Controls 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 38: Safety Controls
Press the on the Feeder and Stacker Reset Light Curtain Buttons 990-FX Light Curtain provides safety for personnel who enter the defined area when the Safety Light Curtain 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.
Page 39: To Resume Normal Operation After An Beam Is Broken
If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved: Push the button on the START MACHINE operator's station Press the Hinge Loaded Button. the Machine 3.Home KVAL Operation/Service Manual...
Page 40: Air Brake On 990-Fx Six Shooter
Air Brake on 990-FX Six Shooter The 990-FX has air brakes on the Six Shooter 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.
Page 41: Tour Of The Machine
Six Shooter from Hopper In-Feed System Lock Back Section Door is delivered from previous machine and fed Faceplate routing into 990-FX for process- and boring for lock ing. and bolt In Pocket Sensor: A through beam that Frame Node...
Page 42: About The Front Section
Carriage Head #1 are used to pro- Heads and Six Shooters parked position and not used. Six Shooters cess a door. are used to process the Carriage Heads #2 - #4 door. Front Section FIGURE 2-4. KVAL Operation/Service Manual 2-12...
Page 43: About The Hinge Carriage
Routs the hinge pocket on the Pre-Drill: Drills pilot holes for jamb and the door at the same time as the insertion of screws on the jamb and counter rotate router. the door. Air Driven. Hinge Carriage FIGURE 2.5 KVAL Operation/Service Manual 2-13...
Page 44: About The Six Shooter System
Quick Change Dump Gate Screw Track- ing Plate Assembly Screw Pick-Off Cylinder Screw Pick Quick Change Off Slide Dump Con- Assembly tainer Hopper Cylinder Screw Delivery Tubes Plate Assembly Air Injected Cylinder Hopper Part Call-Outs FIGURE 2-6. KVAL Operation/Service Manual 2-14...
Page 45 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. Do not put Magnetized Screws in Hopper. Magnetized...
Page 46: About The Six Shooter Assembly
Allows the Six Shooter to the move to the side for Maintenance and Manual application of Hinges Vertical Cylinder: Drives Six Shooter Up and Down Driver Assembly: Vertical Rails: Hinge Application: Six Shooter Call-Outs Hoppers on machine FIGURE 2-7. KVAL Operation/Service Manual 2-16...
Page 47 Maintenance and Manual pressure goes down application of Hinges a set reference level. Vertical Cylinder: Drives Six Shooter Up and Down Driver Assembly Vertical Rails: Hinge Application: Six Shooter Call-Outs Hoppers Separate Array on Floor FIGURE 2-8. KVAL Operation/Service Manual 2-17...
Page 48: Driver Assembly
Factory set to align hinge. Factory set to align hinge. Latch Arm: Latch Arm Cylinder: Latches to H Block Moves latch arm in and out to secure in place. of position Six Shooter and Gear Box Call-Outs FIGURE 2-9. KVAL Operation/Service Manual 2-18...
Page 49: About The Back Section
Machines Hole for Bolt Chip Out Loca- tion: Lock Bore Lock Bore Motor and Drill: Drills locks holes on the face of the door Key Assemblies on the Back Section (View from Front Section) FIGURE 2-10. KVAL Operation/Service Manual 2-19...
Page 50: Back View Of Rear Section
Edge Clamp: Clamps edge of door Edge Clamp: Clamps edge of door Oil Reservoir Lock Bore Extend and Retract Cylinder Deep Lock Bore Limit Shallow Switches Retracted Key Assemblies on the Back Section (Back View) FIGURE 2-11. KVAL Operation/Service Manual 2-20...
Page 51: About The Out-Feed
Hydraulic Tanks for Six to the next machine. Sen- Shooters sors detect position of Supplies hydraulic pressure to door and when to send it operate Six Shooter. out. Key Assemblies on the Out-Feed Section FIGURE 2-12. KVAL Operation/Service Manual 2-21...
Page 52: About The Electrical Panels
Warning: disconnect off. If working on the panel, follow safety protocol as described in Chapter 1. The 990-FX has a Main Electrical Panel and a High Frequency Panel. Below is an overview of the location of assemblies in the panes Component layout in the Panels may vary.
Page 53: High Frequency Panels
For example, door sensors, width adjusts, and tool interfaces. PLC Interface Inputs and Outputs Top Ethernet cable is from PLC Bottom Ethernet goes to Cutter Node Interconnect Bar Sample of a Frame Node FIGURE 2-15. KVAL Operation/Service Manual 2-23...
Page 54: Graphical Sample Of Node Connections
Inputs/Outputs originate from this box and are connected to Nodes. Back Section Node Power Distributed to Points in the machine Screw Driver 2 Screw Driver 1 Network Connections Frame Node Location of Nodes on Machine FIGURE 2.16 KVAL Operation/Service Manual 2-24...
Page 55: Options
Options Options This section describes some of the common options offered by KVAL. Your machine may not have these options. Option BC: Ball Catch Drill assemblies are mounted onto the lock boring section for drilling left hand and right hand doors for drive-in ball catches.
Page 56: 8-0 Foot Door For Fx
1,2,3,and 4 into working posi- tion 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 insert the jamb into the machine. KVAL Operation/Service Manual 2-26...
Page 57: Option H: Securing Split Jambs
During process, The split jamb will auto trigger the fir- ing mechanism of the staple gun. The nail gun will not fire unless the enable button Note: is activated on the Operators Screen and the safety switches are activated by the male split jamb. KVAL Operation/Service Manual 2-27...
Page 58: Option Z: Screw Changing Hoppers
Screw-changing hoppers for changing screw colors. Enables the operator to change or add screws at floor height. Set up containers to catch the screws Select the Manual Screen Tab Press the Quick Dump Hopper Button. Pour new screw style into each hopper. Continue processing doors. Dump Area KVAL Operation/Service Manual 2-28...
Page 59: Description Of The Six Light Panel
ACR Relay is latched. 24VDC This light comes on once the ACR is latch and the 24VDC power Supply is working Stop – Control Power Fourth First Start – Overload Relay Fifth Second E-Stop 24VDC – Third Sixth KVAL Operation/Service Manual 2-29...
Page 60: Machine Start Summary
Machine Start Summary Machine Start Summary This is a summary of the start sequence for the 990-FX Line. Ensure factory air and power is present at the machine. For more information: See “Tour of the Machine” on page 2-11 Ensure the machine main is on.
Page 61 Load Jamb on top of ledge pressing Pay Atten- tightly against fence. tion to the Hand Place- ment and Warning Stickers on the Machine. After Jamb is secure, press the Jamb Clamp to clamp the Jamb Foot Pedal KVAL Operation/Service Manual 2-31...
Page 62 Move out of area beyond Light Curtain When outside of Light Curtain, press the button to Hinge Loaded start the process. Repeat from Step until (Load Jamb) completed. Take Note of the Status Blink codes KVAL Operation/Service Manual 2-32...
Page 63: Initial Powering Operations For The 990-Fx Line
Initial Powering Operations for the 990-FX Line Initial Powering Operations for the 990-FX Line This section describes how to power up and to power down the 990-FX Line. Powering up the system includes: • Applying power to the entire system •...
Page 64: Home The 990-Fx
The 990-FX must go through a homing routine before any operations are performed. The homing routine sets a zero reference from which the 990-FX measures its movement and cutting process. If power is lost or the 990-FX is re-set, the homing routine must be performed again to reset the zero reference...
Page 65: How To Power Down The Machine
Initial Powering Operations for the 990-FX Line How to Power Down the Machine Push the button for each machine, located on the Stop Operator’s Station Shut down the operating system, by selecting Shutdown from the Desktop. Make sure Windows is shutdown completely before Note: turning off the machine.
Page 66: 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-FX. Screen Selection Menu Map Below are the menu selections for the 990-FX.
Page 67: Machine Feed Back
The information generated is as follows:’ General Machine Status Front Section Status Back Section Status Current Servo Positions Use this information to isolate issues if having Note: problems with the machine. KVAL Operation/Service Manual 2-37...
Page 68: About The Main Screen
About the Main Screen About the Main Screen The Main Screen is also the startup screen for the 990-FX. From this screen, all the basic user interface controls are available to run a door. Main Screen FIGURE 2.20 Call-outs “A and B” are commonly used buttons and appear on all the screens.
Page 69: Machine Controls
Shut Down Button 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” on page 2-33 Exit Application Button This button shuts down Interface Program and defaults to the Windows Desktop...
Page 70 Displays the length of the door in process. Door Length: This value is originated from the Preset or may be manu- ally selected. • Displays the “Hand Orientation” of the Door Handling: door in process. Originated form the machine selection. KVAL Operation/Service Manual 2-40...
Page 71 Press to Enable or Disable the Routers in all the Routers: Hinges • Press to Enable or Disable the Predrills in all the Predrill: Hinges. Head 2 Router Initiate for 3 Hinge doors • Press to Enable or Disable the Routers in Head 2 Routers: KVAL Operation/Service Manual 2-41...
Page 72: Lock Group
Face Plate. Face Plate: Face Plate • indicates the backset distance for the each downloaded preset. Lock Backset: • Press to Enable or Disable the Ball Catch. Ball Catch (Option): KVAL Operation/Service Manual 2-42...
Page 73: About Manual Operation
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 2-21. KVAL Operation/Service Manual 2-43...
Page 74: Width Adjust
Speed ous speed, release the button. Clamp and Stop: • Press the button to extend or retract the appropriate door stop. Stop: Stop • : Press to activate the cylinders that clamp the door. Clamp Clamp KVAL Operation/Service Manual 2-44...
Page 75: Lock Manual Control
Use this button if a new Chipout Blocks are installed on the Hinge Carriage section. Press the to start the burn sequence. a new hole will be slowly drilled. the process will automati- cally stop when finished. KVAL Operation/Service Manual 2-45...
Page 76: Screw Delivery Manual Control
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. KVAL Operation/Service Manual 2-46...
Page 77: About The Setup Screen
The first finger represents the positive direc- tion of the ‘Z” axis, the thumb represents the positive direction of the ‘Y” axis, then second finger represents the positive the direction of the ‘X’ axis. KVAL Operation/Service Manual 2-47...
Page 78: Entering Calibration Offsets
Note: 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. Enter the offset positive or negative number in...
Page 79: Calibration Steps For The Lock Location
Note the measurement value and compare to specification If the lock location is correct, there is no need to perform this process, If it is not correct, follow the instructions in See “Adjusting Lock Location” below. Reference Door Lock FIGURE 3. KVAL Operation/Service Manual 2-49...
Page 80 Either process is finishing too soon or later than each other, use the slide controls to match the timing. Note: This is rarely used. In some cases severe climate changes may cause some of the cylinders to become sluggish. KVAL Operation/Service Manual 2-50...
Page 81 Heads are located in the middle of the machine getting read to process the door. The figure below is a view form the back of the machine. Head #1 and #2 Head #3 and #4 KVAL Operation/Service Manual 2-51...
Page 82: 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 83 Reset Count: Push to reset the Daily count of doors. Total: Number of doors pro- cessed from the Initial start up of the machine. Cannot be Reset. Daily: Number of doors pro- cessed through-out the day. This is additive until reset. KVAL Operation/Service Manual 2-53...
Page 84: Glossary Of Common Terms
Bolt Drill The bolt drill is located on the back section, and drills a hole for the bolt. Lock Bore The lock bore is located on the back section, and bores a hole for the lock KVAL Operation/Service Manual 2-54...
Page 85 Glossary of Common Terms KVAL Operation/Service Manual 2-55...
Page 86 System IT Administration This chapter describes the machine controller. The controller is an on board computer that sup- plies the user interface and controls the operation of the machine. With the controller, KVAL can remotely help troubleshoot your machine. Chapter 3 at a Glance...
Page 87: Chapter 3 System It Administration
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-FX con- troller. The location of the Intranet connection is identified in the figure below (RJ45 to Intranet).
Page 88: Network Diagram
It is recommended to set up a back-up schedule to save your data on a regular occur- rence.The KVAL service team would be happy to help. If any questions occur, contact our service team at (800) 553-5825 or at www.kvalinc.com.
Page 89: About Remote Connection To Kval Service
Remote access is a powerful tool to help fix issues that occur with the Vision Line machine. With the remote access, our KVAL service technician is able to observe your user screen in real time, read, and adjust programming code. For Vision Line access, the Intranet connection on the machine controller must have outside access to the Internet.
Page 90 System IT Administration KVAL Operation/Service Manual...
Page 91: Chapter 4 Maintenance Of The 990-Fx
CHAPTER 4 Maintenance of the 990-FX This chapter describes preventative maintenance steps for KVAL 990-FX 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 92: Maintenance Schedule
This should be done in accor- dance with applicable state and/or federal code requirements To view a video of the maintenance process, visit the KVAL website. Select the Video Tab to view videos. http://www.kvalinc.com/...
Page 93 Inspect Inspect all airlines for kinks or rubbing. Lubricate Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 stan- dard hydraulic oil (KVAL PN:SYS-LUBEG). Lubricate Grease ball screw bearings (if applicable). Clean Clean all bearing shafts with clean, dry cloth.
Page 94: 300 Cycle Maintenance Steps
Check vertical bearings for loose screws. Loose screws could cause bearing damage. High Dust Accumulation Areas Lock Bore Area: build up can occur and stop Bolt drill from extending. Front Section: Underneath Car- riage Heads Jamb Clamp area. KVAL 990-FX Operation/Service Manual...
Page 95: 600 Cycle Maintenance Steps
Reverse action when installing trap. Inspect Tooling Inspect the Tooling for wear, (Drill Bits, Cutting Tools, Screw Driver Bits) See “Replacing Bits in the Front Section” on page 4-31 see “Replacing Tooling in the Back Section” on page 4-35 KVAL 990-FX Operation/Service Manual...
Page 96: Lubricate Inside Of Hopper
Check and empty any dust collection units. Clean any dust filters. Dust collection systems vary from machine to machine. Follow manufacturers directions to empty dust collection units. Filters Dust Collection Containers Typical Dust Collection Unit FIGURE 4- 1. KVAL 990-FX Operation/Service Manual...
Page 97: 3,000 Cycle Maintenance Steps
• cracks • wear from rubbing • Ensure tube clamps are tight Inspect all Photo Eyes Inspect all photo eyes secure and tight. Check Nut that attaches Photo Eye to Machine Check Connection to Photo Eye KVAL 990-FX Operation/Service Manual...
Page 98: Inspect Limit Switches
5 or 20 degrees before the limit switch actuates. Inspect Screw Receiver Parts Inspect screw receiver parts on six shooters for cracks or breaks. Inspect: Screw Receiver Spring Split Shell Steel Ring Rubber Ring Steel Ring Replace any parts that are broken. KVAL 990-FX Operation/Service Manual...
Page 99: Inspect Airlines
Refill Lubricators Ensure Air is turned off. Refill all lubricators. Replace fluid if milky or discolored. Use ab ISO 32 stan- dard hydraulic oil (KVAL PN: SYS- LUBEG). Slide locking switch down twist bowl and remove. Refill bowl. Reverse action when installing trap.
Page 100: Grease Ball Screw Bearings
Grease ball screw bearings (if applicable). For a table of lubrication types to use, Lubrication Schedule. Clean Bearing Shafts Clean all bearing shafts with clean, dry cloth. Spray shaft with silicone oil and clean build up grime and dirt. KVAL 990-FX Operation/Service Manual 4-10...
Page 101: 12,000 Cycle Maintenance Steps
Cylinders not holding their position. Inspect Hydraulic Lines Inspect hydraulic lines for loose fittings, leaks and cracks. Inspect hydraulic lines from the source to the end assembly. KVAL 990-FX Operation/Service Manual 4-11...
Page 102: Inspect Ball Rail Shafts
Clean and lubricate all slides and cylinder rods with dry silicone spray. Clean inside Hopper Clean inside hopper with dry sili- ® cone oil and a 3M ScotchBrite pad (or equivalent). Wipe dry with a clean dry rag KVAL 990-FX Operation/Service Manual 4-12...
Page 103: 72,000 Cycle Maintenance Steps
Wash filter and lubricator bowls with soapy water. • Slide lock down to unlock. • Twist bowl to remove it. • Remove filter from Air filter assembly. Inspect and clean or replace if necessary. • Clean bowls and reas- semble. KVAL 990-FX Operation/Service Manual 4-13...
Page 104: Tool Changing Schedule
Changing and inspecting the tooling on a regular basis keeps the door machining process running accurately and efficiently. KVAL recommends using the tables below for reference to change or inspect the machine tooling. Note: Depending on Machine or Option, some of these tools may vary.
Page 105 Tool Changing Schedule Screw Receiver and 6-Shooter Tooling Screwdriver Bits 1,500 cycles Steel Rings 7,500 cycles Rubber Rings 7,500 cycles Screw Receivers 30,000 cycles Split Shells 30,000 cycles Springs 30,000 cycles KVAL 990-FX Operation/Service Manual 4-15...
Page 106: Maintenance No-Goes
• Do not adjust any and all flow controls from factory settings • Do not remove shim stock • Do not Change or Alter any safety assemblies (E-Stops, Gate Locks, etc) • Do not Change programs in PLC’s or PC’s • Do not Alter Electrical Components KVAL 990-FX Operation/Service Manual 4-16...
Page 107: Lubrication Schedule
Lubrication Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 4- 1. Type of Assembly Recommended Schedule Recommended Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...
Page 108: Lubrication Schedule
Lubrication Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 4-2. Type of Recommended Schedule Recommended Assembly Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...
Page 109: Lubrication Requirements
Closed Pillow Block Hub Style Opened Pillow Block parallel perpendicular mount Greasing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N: Lube EP-2). Every 250 hours of operation. Pillow Block Bearings FIGURE 4-2. KVAL 990-FX Operation/Service Manual 4-19...
Page 110: Flange Bearing Housings
X,Y, or Z direction. Greasing Ball Rail Bearing Approximatively 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/ Every 250 hours N: Lube EP-2). of operation. Ball Rail Bearings FIGURE 4-4. KVAL 990-FX Operation/Service Manual 4-20...
Page 111: About Taper Bearings
To identify a , look at the enclosure and verify there are seals Tapered Bearing Housing between the screw and the housing. Tapered Bear- ing Housing Tapered Bearing Seals Tapered Bearing Housing FIGURE 4-6. KVAL 990-FX Operation/Service Manual 4-21...
Page 112: Ball Screw Nut
Ball Screw Drive Assembly. Ball Screw Nut Recommended every 80 Hrs Servo Motor Pillow Block (Hub Style Recommended every 250 Hrs Tapered Bearing Housing Once a Year Ball Screw Drive Assembly FIGURE 4-8. KVAL 990-FX Operation/Service Manual 4-22...
Page 113: Pulley And Idler Shafts
Breakout of Pulley Assembly Pulley in Action Grease IN Note: It is important not to overfill the Idler Shaft. Avoid get- ting excess grease on the belts Grease Out Idler Shaft KVAL 990-FX Operation/Service Manual 4-23...
Page 114: Lubrication Points On The 990-Fx
Lubrication Points on the 990-FX Lubrication Points on the 990-FX Feed System The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Grease Ball Screw Bearings” on page 4-10. Idler Shafts on the Pulleys in...
Page 115 Lubrication Points on the 990-FX Screw Driver The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Grease Ball Screw Bearings” on page 4-10. Some Bearings are layered under plates. Use a Needle adapter to get to hard accesses...
Page 116: Back Section
Lubrication Points on the 990-FX Back Section The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Grease Ball Screw Bearings” on page 4-10. Back View Some Bear- ings are lay- ered under plates. Use a Needle...
Page 117: Heads
Lubrication Points on the 990-FX Heads The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Grease Ball Screw Bearings” on page 4-10. Assemblies shown transparent. Some Bearings are lay- ered under plates. Use a...
Page 118: Servo Motor Assembly
Lubrication Points on the 990-FX Servo Motor Assembly The figure below shows location of the servo motor assemblies. Grease according to intervals described in See “Grease Ball Screw Bearings” on page 4-10. Sample Servo Motor Heads 1 and 2 Assembly...
Page 119: Description Of Air Input System
Description of Air Input System Description of Air Input System There are two types of air inputs on KVAL machinery. Not all machines have lubricator option installed. Check your machine or Air prints to verify installation. Air Input with Lubrication The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine.
Page 120: Air Line Without Lubricator
The air input system takes in shop air and supplies clean dry air (CDA). Shop Clean Dry Air (CDA) t Air Blow Off Input Air On- Off Knob Muffler Air Distribution Block Pressure Gauge with adjust Filter (purge) Air Filter without Lubricators FIGURE 4-15. KVAL 990-FX Operation/Service Manual 4-30...
Page 121: Replacing Bits
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 Router Bit Screw Driver Bits Air Drive Router Motor Location of Bits in the 990-FX Heads FIGURE4- 16. KVAL 990-FX Operation/Service Manual 4-31...
Page 122: 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. FIGURE4- 17. Inspect and clean collet assembly. KVAL 990-FX Operation/Service Manual 4-32...
Page 123 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 FIGURE4- 19. KVAL 990-FX Operation/Service Manual 4-33...
Page 124: Remove And Replace The Screwdriver Bits
This allows for movement of the Six-Shooter assembly away from the machine. Move the Six-Shooter assembly away from the machine-it will move about 1½ inch. This provides room for hands to access the screwdriver bit holders. KVAL 990-FX Operation/Service Manual 4-34...
Page 125: Replacing Tooling In The Back Section
Follow the instructions in this section to change the bits on the Bore Drill, Bolt Drill, and the Face Plate Router. Bolt Drill Motor Machines Hole for Bolt Lock Bore Motor and Drill: Drills locks holes on the face of the door Face Plate Motor and Drill: Routs face plate. KVAL 990-FX Operation/Service Manual 4-35...
Page 126: Option Sb (Cnc Back Section)
When loosening the collet, it may tighten up, crack again and con- tinue. Inspect and clean collet assembly. Insert the new bit into the assem- bly. Collet Wrench Shaft Wrench (1-5/8 '') (PN: 15-00-ER32) (PN: WRENCH026) KVAL 990-FX Operation/Service Manual 4-36...
Page 127: Changing The Bolt Drill
4-38 Note: Make sure the arbor is not bottomed out in the back of the motor. If it is the arbor will not tighten and will damage the collet or other machine parts. KVAL 990-FX Operation/Service Manual 4-37...
Page 128: Collet Torque Values
Collet Torque Values Collet Torque Values KVAL recommends torquing the collets. Torquing adds consistency is important for repeatable machining. Follow the torque tool manufacturers method of torquing. KVAL 990-FX Operation/Service Manual 4-38...
Page 129 Collet Torque Values KVAL 990-FX Operation/Service Manual 4-39...
Page 130 Collet Torque Values KVAL 990-FX Operation/Service Manual 4-40...
Page 131 CHAPTER 5 Troubleshooting the 990-FX System 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. Note: Refer to the Air and Electrical drawings provided with delivery of the machine.
Page 132: About Motion Control
KVAL Machinery. Sequencing: Sequencing is a series of events executed in a predetermined order. Most KVAL machines use a form of sequential motion control. A typical series of events for a KVAL machine are: Move the door into position.
Page 133 Positioning System: • Moves the load. Examples: A motor or a pneumatic cylinder. The Position Feedback. • Provides location information to the controller. Examples: A limit switch, a photo eye, or ferrous eye, a resolver or an encoder KVAL Operation/Service Manual...
Page 134: Troubleshooting Basics
When did the problem first start? • At first Start-Up? • During the Run? When was the last calibration? Is the door true? Use Router Bit Depth Gauge (PN: 432C) to check depth of Bits Check tools for wear. KVAL Operation/Service Manual...
Page 135: Analyze The Sub Systems
What Part of the Machine is not Working? Determine What: Check the Subsystems in the Table Below. What Subsystem is Respon- sible for the Failed Sequence Step. Typical KVAL Machine Sequence TABLE 5-1. Typical Machine Sequence Responsible Subsystem 1. Move Door into Position Feed System 2.
Page 136 • Bad Output: Relay may be stuck • Air Solenoid Valve: May be stuck or not working. Check the Positioning System Follow the circuit from the Controller output to the Load and check for compo- nent failures. KVAL Operation/Service Manual...
Page 137: About A Typical Contactor Control
Control Circuit Common DC - Control Coil for Thermal OverLoad 120 Vac. Should measure Line Voltage here Motor Schematic Drawing of Contactor and Thermal Overload Block Diagram of a Common Contactor Circuit FIGURE 5-16. KVAL Operation/Service Manual...
Page 138: About Contactor Troubleshooting
Rerun the machine and verify that motor runs without tripping the circuit. If the same overload keeps tripping, verify condition. Follow circuit path using the E-Drawing as a reference. a.Common issues: Check for bad wire, bad motor, or if load is too great for cur- rent draw. KVAL Operation/Service Manual...
Page 139: About Typical Vfd Motor Drive Control
An adjustable-speed drive is used to control the motor speed and torque by varying motor input frequency and voltage. A variable-frequency drive (VFD) is used in KVAL machinery to accu- rately drive motors for machining or moving product through the machine. The figure below shows a block diagram of a typical motor drive circuit.
Page 140: About The Vfd
Figure 5- 18 on page 5- VFD models vary in KVAL machines depending on where it is used, voltage requirements and type of PLC used. This is a general view on the VFD. See the machine’s Electrical Print for detailed information.
Page 141: About Vfd Troubleshooting
Note: The number of reset buttons depends on the machine type and option. The fig- ure above shows a machine with 11 VFDs The VFD manuals are located in the Electrical Panels. On some machines, documentation can be found in the operation station in the documen- tation folder. KVAL Operation/Service Manual 5-11...
Page 142: About A Typical Pneumatic Circuit
Note: In this sample set-up, Port A is nor- mally open and Port B is nor- mally closed. If power is OFF, air should be on Port B. Block Diagram of a Pneumatic Circuit FIGURE 5- 21. KVAL Operation/Service Manual 5-12...
Page 143: Typical Pneumatic Assembly
About a Typical Pneumatic Circuit Typical Pneumatic Assembly Pneumatic assembly setups vary in KVAL machines depending on where it is used and air requirements.This is a general overview of a pneumatic assembly. See the machine’s Air Print for detailed information.
Page 144: About Cylinder Operation
Router applies the control voltage to the which directs com- Control Valve pressed air to extend port of the Cylinder are extended deactivating the Cylinder Router Retract Sensor fully extends activating the Router Extend Sensor. KVAL Operation/Service Manual 5-14...
Page 145 Control Valve Cylinder. retract deactivating the Cylinder Router Extend Sensor When the are fully retracted, the is activated. Cylinder Router Retract Sensor senses the voltage from the completing the process Retract Sensor KVAL Operation/Service Manual 5-15...
Page 146: Important Notice About Adjusting Cylinder Speed
However, sometimes machine settling, mechanics be “broken in” may be cause to slightly adjust extend and retraction speed. If more than 1/2 turn on adjustment knobs are needed, call in a specialist or check with KVAL customer service at 1-800-553-5825. KVAL Operation/Service Manual 5-16...
Page 147: Adjusting Cylinder Extend Speed
Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Tip: If Installing a new flow control assembly, shut down the flow control and back out 4 to 5 turns. this position is a good starting point for kine adjust. KVAL Operation/Service Manual 5-17...
Page 148: Valve Bank Locations
Screw Driver 3 Screw Driver 4 In-Feed Ball Catch (Option) Back Section Out-Feed Hopper Valve Banks are Located View From the Back of the at the Top of the Hoppers Machine Location of Valve Banks FIGURE 5-25. KVAL Operation/Service Manual 5-18...
Page 149: Typical Loads Of Valve Banks
• InFeed Drill Up and Down) • Infeed Shift (Optional) • Infeed Shift (Optional) • Door Thickness • OutFeed Drill Up and Down) • InFeed Drill IN • OutFeed Shift (Optional) • 6-8’ to 8-0’ Shift KVAL Operation/Service Manual 5-19...
Page 150: 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. Warning The following checks require the electrical panel to be energized.
Page 151: 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 Operation/Service Manual 5-21...
Page 152 STEP 4: Stop (Amber) If light is OFF go to item on page 5-24. STEP 5: Start (Amber) If light is OFF go to item on page 5-25. STEP 6: 24VDC (Green light is OFF go to item on page 5-25. KVAL Operation/Service Manual 5-22...
Page 153 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 Operation/Service Manual 5-23...
Page 154 Start button. If no voltage, check the 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. KVAL Operation/Service Manual 5-24...
Page 155 Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block. 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. KVAL Operation/Service Manual 5-25...
Page 156: Using Sensors To Trouble Shoot
24 VDC Location of Sensors on 990-FX Figure 5-27 below, shows the typical sensor locations on the 990-FX The “I” designation rep- resents an input to the PLC and the “Q” designation represents an output from the PLC.
Page 157 Q Designators Screw Drive Head Out #3 Screw Drive Head In #3 Width Adjust- Width Adjust- ment Sensors ment Sensors Out Feed Stop After Out Feed Stop Eye Location of Sensors Top View 990-FX FIGURE 5-27. KVAL Operation/Service Manual 5-27...
Page 158: Z Axis And Y Axis Front Section Sensors
Z-Axis ment and also sets the home position. Note: Below is an example of a Standard 990-FX with 3 Carriage Heads. Other Options may include a 4 Carriage Head version or Hoppers that are a separate array to the side. The 4th Carriage option follows the same sensor placements as Carriages 1-3.
Page 159: Axis Sensors Front Section
The sensors are located underneath the Heads. Below is an example of a Standard 990-FX with 3 Carriage Heads. Other Options may include a 4 Carriage Head version or Hoppers that are a separate array to the side. The 4th Carriage option follows the same sensor placements as Carriages 1-3.
Page 160: Network System Overview
Network System Overview Network System Overview A PLC controls the 990-FX. The 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 161: High Frequency Panel Node Connections
• Door width outputs to the stacker. 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 5-31. KVAL Operation/Service Manual 5-31...
Page 162: Frame, Screw Driver, And Back Section Node Locations
Network System Overview Frame, Screw Driver, and Back Section Node Locations Note: Below is an example of a Standard 990-FX with 3 Carriage Heads. Other Options may include a 4 Carriage Head version or Hoppers that are a separate array to the side.
Page 163: Frame Node Connections
In summary, this 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. KVAL Operation/Service Manual 5-33...
Page 164 Network System Overview KVAL Operation/Service Manual 5-34...
Page 165 2-45 calibration feedback 2-35 lock location 2-47 chisels gear box, maintenance schedule replacing 4-17 4-27 collet assembly inspection 4-28, 4-32, 4-33 high frequency panel computer description 2-22 as a PLC home button backing up 3-2, 3-3 KVAL 990-FX Operation/Service Manual...
Page 166 2-22 description user interface 2-37 main screen return material authorization (RMA) 1-14 interface 2-36 returning the product to Kval 1-14 manual operation Right Hand Rule 2-45 interface 2-41 router bit menu map 2-34 replacing...
Page 167 4-18 troubleshooing 5-26 zero-energy start-up x-axis and y-axis locations 5-28 clean up 1-12 service inspect 1-12 connecting your machine to KVAL Service service center, contacting information 1-14 servo drives connections location 5-30 servo positions feedback 2-35 setup screens 2-45...
Page 168 KVAL 990-FX Operation/Service Manual...
Page 172 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...

Kval 990-FX Operation And Service Manual

Chapter 1 At a Glance

Chapter 2 Operation of the 990-FX

Chapter 3 System IT Administration

Chapter 4 Maintenance of the 990-FX

Chapter 5 Troubleshooting the 990-FX System

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Troubleshooting

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