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Kval 990-F4 Operation Manual

Door pre-hanging system
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Operation Manual
Published: November 12, 2021
Innovation, Quality & Honesty
990-F4 Door Pre-Hanging System

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Summary of Contents for Kval 990-F4

  • Page 1 Operation Manual Published: November 12, 2021 Innovation, Quality & Honesty 990-F4 Door Pre-Hanging 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-F 4 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-F4 Operation Manual...

  • Page 5: Table Of Contents

    Table of Contents Chapter 1 at a Glance.............. 1-1 Overview of the 990-F4 ............1-2 Options Available ..................1-3 About this Manual .................1-5 Safety First!................1-6 Safety Sheet Sign-Off Sheet..............1-6 Safety Terminology of Labels..............1-6 Safety Guidelines..................1-6 Lockout-Tagout Guidelines ............1-10 Follow the P-R-O-P-E-R lockout rule of thumb........1-10 Lockout Tagout Procedure............
  • Page 6 About the Electrical Panels............2-21 Description of the Six Light Panel ............2-22 Quick Start ................2-24 Powering Operations for the 990-F4........2-26 How to Power Up the 990-F4 .............2-26 Home the 990-F4................2-27 How to Power Down the 990-F4............2-27 Emergency Shutdown and Recovery ..........2-28 Menu Map of Interface Screens..........
  • Page 7 About Calibration ..............2-40 Before you Calibrate ................2-40 Flow Chart of Calibration ..............2-41 Using the Adjustment Menus ..............2-42 Enter a Positive or Negative Number? ..........2-42 About the Entering Calibrations ............2-43 Lock Location Process................2-44 Fast and Slow Lock Plate Timing............2-45 KVAL 990-F4 Operation Manual...
  • Page 8 Table of Contents 990-F4...

  • Page 9: Chapter 1 At A Glance

    The following information is available in this chapter: Summary of Chapter TABLE 1- 1. Section Name Summary Page This section provides an overview of the 990-F4. It page 1-2 Overview of the 990-F4 includes a general description and a table of available System options...

  • Page 10: Overview Of The 990-F4

    Overview of the 990-F4 Overview of the 990-F4 is designed for both interior and exterior 990-F4 doors and jambs. It will accommodate 1-3/8" and 1-3/ 4" doors with a minimum width of 18" and a maximum width of 48" and door lengths of 6' 8" or 8' 0". The machining sequence includes automatic routing of either 3-1/2"...

  • Page 11: Options Available

    Light will be mounted on the out-feed end of the 990-F4 that can be seen by the 700-C Assembly Table operator. The light will be on when the door in the 990-F4 is being machined as a right hand door and off for a left hand door.
  • Page 12 Overview of the 990-F4 Option Title Description Option K Eight-Shooter Screw Gun for 4" X To attach 4" X 4" hinges to the door and jamb, No. 10 by 3/4" long flat 4" Hinge head screws are automatically sorted and fed, eight (8) at a time, to the screw gun.

  • Page 13: About This Manual

    Overview of the 990-F4 About this Manual This manual is part of a package delivered with the machine line. Integration Package includes the following: includes the following: Operation Manual Chapter Title Description Introduction Descriptions of Machine Line and Safety Information.

  • Page 14: Safety First

    See “Safety Sign-Off Sheet” on page 1-21. 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 15 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 1-11. KVAL 990-F4 Operation Manual...
  • Page 16 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-F4 Operation Manual...
  • Page 17 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 18: 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-F4 Operation Manual 1-10...

  • Page 19: 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-F4 Operation Manual 1-11...

  • Page 20: 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-F4 Operation Manual 1-12...

  • Page 21: 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 1-15.
  • Page 22 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 990-4 Operation Manual 1-14...

  • Page 23: Getting Help From Kval

    • Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485 • Email address is service@KVALinc.com • Hours: 6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday 6:30 AM to 1:30 PM Pacific Standard Time, Friday KVAL 990-F4 Operation Manual 1-15...

  • Page 24: Kval Return And Warranty Policy

    KVAL Return and Warranty Policy KVAL Return and Warranty Policy KVAL's goal is to provide customers with high quality products. If, for any reason, you are not completely satisfied with your purchase, please contact us at: Email: parts@kvalinc.com +1 (800) 553-5825 Phone: •...

  • Page 25: Customer Errors

    Kval provides a warranty to products that are deemed defective. Within 30 days of discovery of said defect, please notify Kval, but no more than one (1) year after delivery will the product be covered under Warranty. The repair, replacement, or payment in the manner described above shall be the exclusive remedy of Buyer for breach of Kval’s warranty or for claims based upon failure...

  • 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-F4 Operation Manual 1-20...

  • 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-F4 Operation Manual 1-22...
  • Page 31 Operation of the 990-F4 CHAPTER 2 Chapter 2 at a Glance The following information is available in this chapter. Section Name Summary Page Typical Line Setup. page 2-2 Machine Description Descriptions of the operation of the parts and assemblies page 2-5 Operator’s Tour...

  • Page 32: Machine Description

    This manual will focus on the 990-F4 The 990-F4 Process Summary • Cut a hinge pocket on a door and jamb (Carriage Assembly) • Drill pilot holes for the hinge screws (Carriage Assembly) • Apply hinges.(Six Shooter) •...

  • Page 33: Machine Components

    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 990-F4 Operation Manual...

  • Page 34: Typical Production Line

    558 Door Trim- PLC Controlled 990-F4: Machines door and jamb for four hinges and lock 700-C: Attaches strike jamb and header to hinge jambed door from the 990-F4 Typical System Setup with 990-F4 FIGURE 2-1. KVAL 990-4 Operation Manual...

  • Page 35: Operator's Tour

    Hinge Carriage Back Section Hinge Carriage Lock Bore Assembly Hinge Carriage Valve Bank #2 Hinge Carriage Shooter Out-Feed Router and Valve Bank #2 Screw Predrill Hopper Electrical Panel # 2 Top View of 990-F FIGURE 2-2. KVAL 990-F4 Operation Manual...

  • Page 36: 990-F4 With Dual Hopper

    Operator’s Tour 990-F4 with Dual Hopper with the Dual Hopper option performs the same as a Standard 990-F-4 except it has two 990-F4 Hoppers feeding to the 6 Shooter. Each hopper can be filled with different colored screws. Indi- vidual hoppers that can be selected at the Main screen. the two hoppers cut down setup time when changing screw colors.

  • Page 37: About The 990-F4

    Door through the machine. In-Feed System: Door Enters Machine here. Sensors triggered Hydraulic Tank for and width is Six Shooter: Sets adjusted to door and Lifts Six Shooter out of Hinge pocket 990-F4 In-feed FIGURE 2-4. KVAL 990-F4 Operation Manual...

  • Page 38: About The Front Section

    • Machine Control • Foot Pedal • Hinge Carriages 1 through 4 Machine Control Operator Station Six Shooter Hinge Car- Hinge Carriage Hinge Carriage Hinge Carriage Gauges riage # 1 Foot Pedal 990-F4 Front Section FIGURE 2-5. KVAL 990-4 Operation Manual...

  • Page 39: Option: Securing Split Jambs

    During process, press the button. Fire Side Nailer Note: The nail gun will not fire unless the enable button is activated on the Operators Screen and the safety switches are activated by the male split jamb KVAL 990-F4 Operation Manual...

  • Page 40: About The Operators Station

    • E-Stop (Option) sets and displays buttons to calibrate the machine. Some Options Combine Machine Lines into one Operators Station. For example this configuration com- bines the Handler, a 558 and the 990- 990-F4 Handler KVAL 990-4 Operation Manual 2-10...

  • Page 41: About The Machine Control

    Select able Auto Feed” button out (LH) door. (An optional AUTO 'Feed Through' passed the door will place the 990-F4 in the position allows the 990 to through the 990F-4 without feed mode selected by the receive hand information from machining.

  • Page 42: About The Hinge Carriage

    Gauges located on the front frame display air pressure ratings of key assemblies. Gauge orienta- tion may vary with option of machine. Below is a typical array of gauges. Door High Vertical Gauge is located on the Note: Refer to Air Schematics and labels for correct psi ratings. bottom KVAL 990-4 Operation Manual 2-12...

  • Page 43: About The Six Shooter System

    Hopper Screw Delivery Hoses Operator Controls Magnetic Indexing Fixture. Hinge is Placed Here Drive Assembly: • Air Motor • Gearbox • Six Screw Driver Bits Photo of Six Shooter FIGURE 2-7. KVAL 990-F4 Operation Manual 2-13...

  • Page 44: About The Six Shooter Controls

    It is also helpful when replacing bits or doing maintenance on 3-degree bevel front section. Just plunge the head and flip the trap out of position. This will allow the head to retract to the back position. KVAL 990-4 Operation Manual 2-14...

  • Page 45: About The Hopper

    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. Magne- tized screws can cause sluggish response to screws getting stuck.
  • Page 46 ) 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 on the Six Shooter panel located mid machine on the front Reset section. Fill the Hopper with new screws. KVAL 990-F4 Operation Manual 2-16...

  • Page 47: Driver Assembly

    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 FIGURE2- 9. KVAL 990-F4 Operation Manual 2-17...

  • Page 48: About The Overhead Track

    The Six Shooter, which is supported on ball bearing equipped steel wheels and is mounted on an overhead track. The track and the Six Shooter are precisely aligned to ensure the hinge is properly positioned into the pocket at each hinge location. KVAL 990-F4 Operation Manual 2-18...

  • Page 49: About The Back Section

    Chip Out Location Drills locks holes on the face Face Plate a LH or RH door of the door Motor and Drill: Routs face plate. Key Assemblies on the Back Section FIGURE2- 10. KVAL 990-F4 Operation Manual 2-19...
  • Page 50 Red Light On, indicates a right Hand Door is coming out to the 700. Light OFF, indicates a Left Hand Door is coming out Black Button Resets 700 Key Assemblies on the Out-Feed Section FIGURE2- 11. KVAL 990-F4 Operation Manual 2-20...

  • Page 51: About The Electrical Panels

    High Voltage Section 110 V / 24 V Ter- minals Input / Output Terminals Input / Output High Voltage Terminals Section Servo Drive Galil DMC VFD Section Electrical Panel and High Frequency Panel FIGURE 2-12. KVAL 990-F4 Operation Manual 2-21...

  • Page 52: Description Of The Six Light Panel

    Sensors are electronically tripped while limit switches are mechanically tripped. It is important to keep the sensors cleaned and aligned to keep the door process running smoothly. There are two classifications of sensors: Photo Electronic and Inductive Proximity Sensor. KVAL 990-F4 Operation Manual 2-22...
  • Page 53 The Limit Switch is activated by an assembly moving a switch arm. • .Depending on the model of limit switch, the amount of “pre-travel” (amount of movement from the arms resting position) is either 5 or 20 degrees before the limit switch actuates (Clicks). Switch Arm KVAL 990-F4 Operation Manual 2-23...

  • Page 54: Quick Start

    Ensure factory air is present at the machine and the main air supply valve 990-F4 is turned on. Power up the . See “How to Power Up the 990-F4” on page 2-26. 990-F4 Home the by pressing the button. See “Home the 990-F4” on...
  • Page 55 Shooter or pressing the Jamb Clamp foot pedal To continue, repeat from the section in this quick start. If Load Door completed, shut down the machine. See “How to Power Up the 990- F4” on page 2-26 . KVAL 990-F4 Operation Manual 2-25...

  • Page 56: Powering Operations For The 990-F4

    • Shutting down the control power • Removing power from the entire system How to Power Up the 990-F4 Ensure factory air is applied to machine and main air supply is turned on. Check that all E-Stop buttons are out and safety gate door s are closed.

  • Page 57: Home The 990-F4

    Push the green button to the CONTROL TRANSFORMER OFF position. Step1 KVAL also recommends that you turn the disconnect switch on the electrical cabinet to OFF; this helps reduce possible damage resulting from power surges from electri- cal storms. Step 3...

  • Page 58: Emergency Shutdown And Recovery

    Powering Operations for the 990-F4 Emergency Shutdown and Recovery There are emergency shutdown (E-Stop) switches located at key points around the machine. Note: Depending on options of the machine, the E-Stop buttons may be located at various locations and of...

  • Page 59: Menu Map Of Interface Screens

    Load Hopper Speed Control Door Stop / Clamp Reset Machine Shift IN Pocket Lock Enable/ Disable Feed Control Shut Down System Shift OUT Pocket Test Mode Home Machine Skip Hinges Exit Application Hinge Chipout On/Off KVAL 990-F4 Operation Manual 2-29...
  • Page 60 3.5'' Hinge 4.0'''' Hinge See “About the Diagnostic Screen” on Diagnostic Screen page 2-39. Door Count Machine Controls Daily Count Stop Door Seq Total Count Reset Machine Daily Reset Shut Down System Home Machine Exit Application KVAL 990-F4 Operation Manual 2-30...

  • Page 61: Machine Feed Back

    The information generated is as follows:’ General Machine Status Front Section Status Back Section Status Current Servo Positions Note: Use this information to isolate issues if having prob- lems with the machine. KVAL 990-F4 Operation Manual 2-31...

  • Page 62: About The Main Screen

    • Choose up to 12 different stored back section presets to process doors • Get access to load and modify presets • Turn ON or OFF assemblies on the machine to custom cut doors • Navigate to other screens Main Screen FIGURE 2-13. KVAL 990-F4 Operation Manual 2-32...

  • Page 63: Machine Buttons

    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 “Powering Operations for the 990-F4” on page 2-26 Exit Application This button exits the and jumps to the Interface Windows Desktop.

  • Page 64: Preset Buttons

    • Choose between 0 degree or 3 degree bevel. Hinge Bevel: • Choose to move Carriage Head into machin- Shift Into Pocket and Shift Out of Pocket: ing mode or out of the machining mode. KVAL 990-F4 Operation Manual 2-34...

  • Page 65: Screw Setup Controls

    Lock setting ON or OFF. • Press to toggle parameters. (Option) Lock Backset: Backset • is the normal operating process (No Extend Time), Select to Fast Lock Plate Timing toggle Fast Lock Timing On or Off. KVAL 990-F4 Operation Manual 2-35...

  • Page 66: About The Manual Screen

    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 990-F4 Operation Manual 2-36...

  • Page 67: Lock Jog

    Narrow Door Recovery: If a narrow door gets stuck in a machine, push this button to lift and unclamp. Door can then be moved manually out of the machine. KVAL 990-F4 Operation Manual 2-37...

  • Page 68: Hinge Jog

    Manually inject air into the 6-shooter to clear a stuck 6 Shooter Manual Air Injection: screw. This action can also can be operated at the 6-Shooter assembly. Note: For instruction on how to name the Hopper Buttons, See “About Calibration” on page 2-40. KVAL 990-F4 Operation Manual 2-38...

  • Page 69: About The 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 70: About Calibration

    This chapter describes how to use the Calibration routine. Before you Calibrate Note: Before calibration, KVAL recommends that a test run be performed. A test run will not operate the machine but will NOT extend the cutting tools. Using this function allows the operator to observe any major issues during the machine cycle without damaging tooling or product.

  • Page 71: Flow Chart Of Calibration

    About Calibration Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the 990-F4 Calibration Process Flowchart FIGURE 2- 15. KVAL 990-F4 Operation Manual 2-41...

  • Page 72: Using The Adjustment Menus

    • The thumb represents the positive direction of the ‘Y” axis • The Second finger represents the positive the direction of the ‘X’ axis. Y Axis Positive movement Z Axis Positive movement X Axis Positive movement KVAL 990-F4 Operation Manual 2-42...

  • Page 73: About The Entering Calibrations

    About Calibration About the Entering Calibrations Press the to jump to the Setup Menus. Setup Button Machine Calibration Screen FIGURE 2-17. KVAL 990-F4 Operation Manual 2-43...

  • Page 74: Lock Location Process

    Note the measurement value and compare to specifica- tion If the lock location is correct, there is no need to perform this process, If it is not correct, follow the instructions above. KVAL 990-F4 Operation Manual 2-44...

  • Page 75: Fast And Slow Lock Plate Timing

    Continue entering numbers until timing is matched. Hopper Names Enter the type of screws (color) in the text boxes. The names assign here appear on the screen in the Screw Main Setup section. KVAL 990-F4 Operation Manual 2-45...
  • Page 76 About Calibration KVAL 990-F4 Operation Manual 2-46...
  • Page 77 2-31 electrical panels general 2-31 description servo positons 2-21 2-31 emergency shutdown machine status description general feedback 2-28 2-31 e-stop light main electrical panel description description 2-22 2-21 menu map 2-31 feed system timing KVAL 990-F4 Operation Manual...
  • Page 78 2-33 six light panel description 2-22 sequence list 2-22 start light description 2-22 start machine button power up 2-26 stop light description 2-22 stop sequence button description user interface 2-33 KVAL 990-F4 Operation Manual...
  • Page 80 Customer Service Contacting KVAL 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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