Page 1 Operation Manual Published: December 14, 2022 Innovation, Quality & Honesty 990-APEX Door Machining System Architectural, Pre-Hanging, and Exterior Doors ® With KvalCAM...
Page 2 Mon-Thu:6:00 AM - 4:00 PM PST Fri: 6:00 AM - 3:30 PM PST Parts Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web- site at the “Contact Us” page. email: parts@kvalinc.com KVAL 990-APEX Operation Manual...
Page 3 KVAL 990-APEX Operation Manual Technical Support For machinery support and troubleshooting. Call, email, contact us on our website at the “Contact Us” page. Mon-Fri:4:00 AM - 4:00 PM PST email: support@kvalinc.com Field Service Support For any other inquiries or to schedule on-site service. Call, email, contact us on our website at the “Contact Us”...
Page 4 LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE KvalCAM SOFTWARE. Kval Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You are the purchaser of Machinery operated by the KvalCAM Software are the “Licensee”.
Page 5: Table Of Contents
Table of Contents Chapter 1 Introduction to the 990-APEX System Overview of the 990-APEX ............1-2 Architectural, Pre-Hanging, & Exterior -- All in One ......1-2 KvalCAM....................1-3 990-APEX Summary................1-3 Specifications Summary ...............1-4 About this Manual ..............1-5 Operation Manual .................1-5 Service Manual ..................1-5 KvalCAM Reference Manual ..............1-5...
Page 6 Safety Sign-Off Sheet .............. 1-22 A Note to the Operator................1-22 Chapter 2 Operation of the 990-APEX Powering Operations for the 990-APEX ........2-2 Steps Before Powering the 990-APEX ..........2-2 Powering the APEX ................2-3 Home the 990-APEX ................2-3 How to Power Down ................2-4 About Emergency Stops ............
Page 7 Calibration of the Machine Line About Calibration ..............3-2 About the Calibration Menus and the Calibration Reference Cut ..3-2 Before you Calibrate ................3-2 About the 990-APEX Calibration Screen ......... 3-3 990-APEX Calibration Screen ..............3-3 Calibration Sections................3-3 Unlock the Calibration (Option).............3-4 How to Enter Calibration Data ..........
Page 8 Performing the Hinge Tooling Calibrations .........3-24 Verifying the Hinge Chisels Calibration..........3-24 Adjusting the Hinge Chisels Calibrations..........3-25 Step 8: About the B-Side Door Stop Calibration ...... 3-26 Tools Needed..................3-26 About the B-Side Calibration Shape ...........3-26 Verify and Adjust the B-Side Door Stop Calibration......3-26 990-APEX Operation Manual...
Page 9 Machine Terms ................ 4-2 Overview of Machine ............... 4-4 990-APEX with Standard Hoppers ............4-4 990-APEX with RTS Rotary Hoppers ...........4-5 About the Controls of the 990-APEX ........4-6 About the Operators Station ..............4-6 About KvalCAM ..................4-7 About the Door/Jamb Clamp Foot Pedal ..........4-7 About the Local Machine Controls............4-8...
Page 10 Control Panel Part Descriptions............4-34 About the Hopper..............4-35 Hopper Part Descriptions..............4-36 Hopper Process ..................4-36 About the RTS Rotary Hopper..........4-38 Operation ....................4-38 RTS Eight Shooter Option ..............4-39 About the Driver Assembly ............4-40 Driver Assembly Part Descriptions .............4-41 990-APEX Operation Manual...
Page 11 Option Z and Z1: Quick Screw Change ........4-71 Quick Change Part Descriptions............4-71 Quick Change Process ...............4-72 Option N: Weather Strip Brackets..........4-73 Option O: Air Blow Off.............. 4-74 Option SJ: Securing Split Jambs ..........4-75 About the Staple Gun .................4-75 Split Jamb Process ................4-76 990-APEX Operation Manual...
Page 12 Table of Contents 990-APEX Operation Manual...
Page 13: Chapter 1 Introduction To The 990-Apex System
This chapter provides an overview of the and important Kval 990-APEX Door Hanging System safety information to follow when operating the machine. Chapter 1 at a Glance Overview of the 990-APEX ..............1-2 About this Manual ................. 1-5 Safety First! ..................1-6 Safety Guidelines .................
Page 14: Overview Of The 990-Apex
Overview of the 990-APEX Overview of the 990-APEX Architectural, Pre-Hanging, & Exterior -- All in One redefines door and jamb machining flexibility by bridging the interior, exterior, 990-APEX and architectural/commercial markets. Designed with 75 years of experience and proven concepts at the foundation of our legendary , the APEX easily outperforms the competition.
Page 15: Kvalcam
Overview of the 990-APEX Lock Section FIGURE 1-2. Jambs - The can machine and attach 3 ½” or 4” hinges with original patented 6- 990-APEX Kval’s Shooter and 8-Shooter technology for pre-hanging interior and exterior doors. allows KvalCAM the door and jamb to be machined separately to accommodate special hinges and strikes, such as ASA strikes and three-point lock strike jambs.
Page 16: Specifications Summary
Overview of the 990-APEX • Laser Encoder for real-time door thickness measurement and program adjustment for correct hardware • CNC Ball-catch Motors for varying size, location, face plates, pivots, and flush bolt top/bottom plates • Variable Run Modes of pre-hanging, door-only, and/or jamb-only are fully sup- ported •...
Page 17: About This Manual
Maintenance steps for the machine line KvalCAM Reference Manual KvalCAM Reference Manual includes the following: Chapter Title Description KvalCAM Reference Description of the Interface KvalCAM Examples Examples of Common Door Job Features KvalCAM Common Terms Common terms associated with KvalCAM 990-APEX Service Manual...
Page 18: Safety First
• DANGER means if the danger is not avoided, it will cause death or serious injury. • WARNING means if the warning is not heeded, it can cause death or serious injury. • CAUTION means if the precaution is not taken, it may cause minor or moderate injury. 990-APEX Service Manual...
Page 19: Safety Guidelines
• Never reach hands beyond safety cage. Servo motors can unexpectedly move quickly. • Never clear screws or hinges out of the machine while it is running. • Never reach into the router area to retrieve a hinge. The router may still be running down after shut down. 990-APEX Service Manual...
Page 20: Compressed Air
Electrical circuitry on this machine is protected by an approved lockable disconnect circuit. In addition to this equipment, you must install an approved disconnect for the electrical power sup- plying this machine Electrical Panel Labels FIGURE 1- 6. 990-APEX Service Manual...
Page 21 Some machines are powered by more than one supply located at different locations. Do not open the cabi- nets without High Voltage training or without permission from a supervisor. 990-APEX Service Manual...
Page 22: Pinch Points
Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, the electrical and air pressure systems. This should be done in accor- Lockout Tagout dance with applicable state and/or federal code requirements Maintenance Warning Labels FIGURE 1-8. 990-APEX Service Manual 1-10...
Page 23: Laser Warnings
Kval of this machine Follow Your Company’s Safety Procedures In addition to these safety guidelines. Your company should have on-site and machine specific safety procedures to follow. 990-APEX Service Manual 1-11...
Page 24: 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-APEX Service Manual 1-12...
Page 25: Lockout Tagout Procedure
OFF position. ensure the lever is in the down position, insert Lever style Electrical Panels: lock and tag into the lever hole making sure the lever cannot move, lock as per the tagout guidelines. (see illustration below). 990-APEX Service Manual 1-13...
Page 26: Lockout Tagout Air Supply
Maintenance or repairs may started. Post Maintenance Steps After maintenance is completed, the person performing the work must ensure all tools, spare parts, test equipment, etc., are completely removed and that all guards and safety devices are installed. 990-APEX Service Manual 1-14...
Page 27 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-APEX Service Manual 1-15...
Page 28: 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 See “Getting Help from Kval” on page 1-18. Kval Technical Support. Check Controls Confirm that all switches are in the “OFF” position. Please be advised that some components of the machine may start automatically when energy is restored.
Page 29: Close The Cage Gate
Zero-Energy to Start-Up Close the Cage Gate Verify all cage gates are securely closed. Ensure all safety protocols are in effect. Kval 990-APEX Service Manual 1-17...
Page 30: Getting Help From Kval
Getting Help from Kval Getting Help from Kval Before you seek help, first try the troubleshooting procedures. Follow the procedures below. If you are unable to resolve the problem: Locate the machine’s Specification Plate and record the serial number, 3 phase volts, electrical print number, and air print number.
Page 31: Kval Return And Warranty Policy
Kval Return and Warranty Policy Kval Return and Warranty Policy goal is to provide customers with high quality products. If, for any reason, you are not Kval's completely satisfied with your purchase, please contact us at: Email: parts@kvalinc.com +1 (800) 553-5825 Phone: •...
Page 32: Customer Errors
Kval Return and Warranty Policy Customer Errors If the item is to be returned due to customer ordering error, the customer must return the item to or the shipper of origin at its expense. A 15% restocking fee may apply to manufactured...
Page 33 Kval Return and Warranty Policy Page Intentionally Left Blank 990-APEX Service Manual 1-21...
Page 34: Safety Sign-Off Sheet
It is recommended you make a copy of this sheet for new operators. If a copy is Note: needed, you may download a PDF at the website (http:// Kval www.kvalinc.com). You may also contact our at (800) Technical Service Support 553-5825 or email at support@kvalinc.com. 990-APEX Service Manual 1-22...
Page 35: Chapter 2 Operation Of The 990-Apex
This chapter describes the user interface of the . The content is geared to help operators 990-APEX understand the basic operation of the machine. Chapter 2 at a Glance Powering Operations for the 990-APEX ..........2-2 About Emergency Stops ............... 2-5 Before Processing a Door ..............
Page 36: Powering Operations For The 990-Apex
Powering Operations for the 990-APEX Powering Operations for the 990-APEX This section describes how to power up and power down the 990-APEX. Learn all safety precautionary controls on the machine. Important: Powering up the system includes: • Applying power to the entire system •...
Page 37: Powering The Apex
The following actions will Home Main Screen occur. a.The machine will move to the home position at the end of the machine. A-Side b.The machine will then move to its neutral position The 990-APEX s now ready for work. 990 APEX Operation Manual...
Page 38: How To Power Down
Powering Operations for the 990-APEX How to Power Down Click the ® button at the bottom left corner of the screen. Windows Start Click the icon and select Power Shut Down Wait for the machine to power off. Switch the green switch to the position.
Page 39: About Emergency Stops
About Emergency Stops About Emergency Stops Caution: Learn all safety precautionary controls on the machine. Depending on the model of machine, there are emergency shutdown ( E-Stop switches located at key points around the machine. switches are to be used when the machine is out of control or is about to E-Stop damage personnel or equipment.
Page 40: Before Processing A Door
Step 1: Pre-Process Steps and Home the Machine Ensure factory air is present at the machine and the main air supply valve 990-APEX is turned on. Power up the See “Powering Operations for the 990-APEX” on page 2-2. 990-APEX At the screen select the button.
Page 41 Before Processing a Door Step 2: Load a Door Job Load a Door Steps FIGURE 2-2. Refer to Figure 2-2, for selection locations in the process below. Note: Select the at the upper left side of the screen. Libraries Tab Select the Door Job Library Tab From the table, double-click the desired job to open the...
Page 42 Before Processing a Door Step 3: Open the Main 990-APEX Screen After the is loaded into , select the tab. At this screen, the opera- Door Job Queued Jobs 990-APEX tions to be performed are displayed. Verify the settings or set them to the desired settings.
Page 43: About Processing A Door
After performing the steps in “Before Processing a Door” on page 2-6, follow the steps in this section. When the receives the 990-APEX Door Job • The machine automatically adjusts the door-fence servo to accommodate the incoming door. • The move into position.
Page 44 About Processing a Door Step 2: Load the Jamb s. See Place the jamb securely on the located behind the Jamb Shelf H-Block Figure 2-5 below. Secure the jamb against the Jamb Stop To clamp the jamb, hold the jamb in place with hands in the proper position and press the foot pedal to activate the jamb clamps.
Page 45 About Processing a Door Auto Start 1 is enabled, the cutting process will start automatically after the opera- tor leaves the cutting area. If is not enabled, select the Auto Start Start Sequence button to start the process. See Figure 2-7 below.
Page 46: Process
About Processing a Door Process Figure 2-9 below shows control locations and a summary of the process steps. Shooter For a full description of the assembly, see “About the Six/Eight Shooter Note: Shooter System” on page 4-30. Clear Screws Button Load/Un-Load Button Un-Clamp and Feed Out Door Unclamp Button...
Page 47 About Processing a Door Move the tight into the and select the button. Shooter H-Block Start Sequence a.The hook and latch activate, pulling the in tight to the door and jamb. Shooter Shooter locked into the H-Block Put Shooter into H-Block FIGURE 2-11.
Page 48 About Processing a Door Step 5: Door Feed-Out When finished with all the hinges, press the button located on the Unclamp Shooter. Figure 2-13 below. An option to feed out the door is to press at the screen Note: Toggle Door Clamp Main or press the foot pedal.
Page 49: About Machine Feedback
Hinge Carriages • Lock Carriage is idle but ready to work. • Table is feed system is off. • When activated, the tab will highlight. Software Revision Machine Feedback 990-APEX Machine Feedback FIGURE 2-14. 990 APEX Operation Manual 2-15...
Page 50: About The 990-Apex Interface Screens
About the 990-APEX interface Screens About the 990-APEX interface Screens are created in and are processed at the interface screens. For information Door Jobs KvalCAM about , see the separate document, KvalCAM KvalCAM Reference Guide. Select the tab at the upper left to get access to the interface screens.
Page 51: About The Main Control Screen
• Software buttons to control the actions of the machine. Machine Controls: • Information about the selected Door Job (tasks and parameters) Machine Tasks: Machine Tasks Machine Controls 990-APEX Main Screen FIGURE 2-15. 990 APEX Operation Manual 2-17...
Page 52: About The Machine Controls Section
About the Machine Controls Section About the Machine Controls Section This section describes the controls that run the machine. Match the corresponding letter in Figure 2-16 below to the sections in this chapter. Controls Section FIGURE 2-16. Links to Control Descriptions TABLE 2-2.
Page 53: About The Main Control Section
About the Machine Controls Section About the Main Control Section Under Main Control, upper level controls are located. The background for enabled buttons have an orange background or have gray background in the disable mode. Table 2-3 below includes descriptions of the selections.
Page 54: About The Auto Control Section
About the Machine Controls Section About the Auto Control Section Under , enable or disable automatic machine operations. Auto Control The background for enabled buttons have an orange background or have gray background in the disable mode. Table 2-4 below includes descriptions of the selections.
Page 55: About The Sequence Control Section
About the Machine Controls Section Stop and Clamp Control Selections FIGURE 2-19. Stop and Clamp Control Descriptions TABLE 2-5. Sections Description Toggle Door Stop Select to activate or deactivate the Door Stops. Toggle Door Clamp Select to activate or deactivate Door Clamps. Note: The mechanical foot pedal button is most commonly used.
Page 56: About The Manual Control Section
About the Machine Controls Section Control Section Descriptions TABLE 2-6. Sections Description Select the Start Sequence button at the interface or at the B-Side of the Start Sequence machine to start the machining process. Auto Feed (Pause) Select Auto Feed to pause the door feed. Select to pause the auto feed. Select again to continue the feed.
Page 57: About Speed Control
About the Machine Controls Section Manual Control Section Descriptions TABLE 2-7. Sections Description Jog Feed Forward Select and hold button to continuously feed the door forward through the machine. Tap to move in increments. Jog Feed Reverse Select and hold button to continuously to reverse the feed of the door through the machine.
Page 58: About The Job Parameters And Task Section
About the Job Parameters and Task Section About the Job Parameters and Task Section This section describes the parameters of the Match the corresponding letter in Figure 2- Door Job. below to the sections in this chapter. Task Section FIGURE 2-22. Links to the Job Parameters and Task Descriptions TABLE 2-8.
Page 59: About The Door Job Specification Top Bar
About the Job Parameters and Task Section About the Door Job Specification Top Bar At the top of the screen, feedback about the current is displayed. Main Control Door Job Table 2-9 below includes descriptions of the Top Bar Door Job Specifications FIGURE 2-23.
Page 60: About Hinge Task Controls
About the Job Parameters and Task Section About Hinge Task Controls In this part of the interface, related feedback is grouped and displayed. Hinge Carriage- Included are: • The status of each Head (Hinge Carriage) • Locations H-Block • Hinge Cut Parameters Table 2-10 below includes descriptions of the Hinge Task Controls.
Page 61: About Head Status
About the Job Parameters and Task Section About Head Status Each operational status is displayed in text boxes. Hinge Carriage Head 1- 4 Figure 2-25 shows examples of each status available indicated by icon color and text. Table 2-11 below includes descriptions of each status. Head Status Examples FIGURE 2-25.
Page 62 About the Job Parameters and Task Section Figure 2-27 below shows the reference points of a right hand door process. The A-Side Door Stop is extended. Each location is derived from the stop to the leading edge of each H-Block H-Block Door Top Stop “A”...
Page 63: About Hinge Cut Location And Length
About the Job Parameters and Task Section About Hinge Cut Location and Length The location and length of each hinge cut is displayed in the text boxes. Location Length Hinge Cut Location and Length Interface FIGURE 2-29. Figure 2-30 below details the location and length parameters of the hinges for a left hand door as shown in Figure 2-29 above.
Page 64: About The Shelf Pin Config
About the Job Parameters and Task Section About the Shelf Pin Config Under , shelf pin lengths are displayed. The door thickness is determined by the Shelf Pin Config or thickness input from the . Using the door thickness and the jamb Thickness Probe Door Job width, the shelf pin length is calculated and displayed.
Page 65: Installing Shelf Pins
About the Job Parameters and Task Section Installing Shelf Pins Install the shelf pins into the behind the Jamb Shelf H-Blocks Shelf Pin H-Block Jamb Shelf Rear View of Jamb Shelf FIGURE 2-32. Jamb Resting on Jamb Shelves Jamb in Machine FIGURE 2-33.
Page 66: About The Shooter Controls
Shooter In the version of the controls are included. The operator RTS Rotary Hopper 990-APEX Hopper selects the desired button. The selected automatically indexes into position, deliv- Hopper Hopper ering the screws to feed to the Shooter Hinge-Applicator.
Page 67: About The Lock Tasks Control
About the Job Parameters and Task Section About the Lock Tasks Control Under , lock cut information is displayed. Lock Tasks Control Figure 2-35 below shows an example of a lock cut, including: • A lock cut on the face of the door •...
Page 68 About the Job Parameters and Task Section Figure 2-36 below details the location and length of the lock cuts that are shown in Figure 2-35 on page 2-33. Lock Length (Diameter): 0.875 Length (Diameter): 2.250 Location 2.063 Location 38.875 Face Length (Diameter): 2.125 Location 38.938 Lock Tasks Controls...
Page 69: About The Manual Servo Control Screen
About the Manual Servo Control Screen About the Manual Servo Control Screen To go to this screen, select the tab. Manual Servo Control This function is ordinarily used in troubleshooting. For example, checking cut Note: specifications, and maintenance. At this screen, the operator can: •...
Page 70: Manual Servo Movement Direction
About the Manual Servo Control Screen Manual Servo Control Descriptions TABLE 2-15. Action Description Hinge Head 1-4 Select and hold the Forward or Reverse buttons to move Carriages: Lock Head X-Axis (Across the machine) Y-Axis (Vertically-Up and Down) Z-Axis (Into and out of the machine) Jamb Head Axis Select and hold the Forward or Reverse buttons to move the Jamb Head across the machine.
Page 71 About the Manual Servo Control Screen Figure 2-39 below shows the forward and the reverse direction of the Lock Head Y-Axis Forward X-Axis Forward Z-Axis Forward Z-Axis X-Axis Reverse Reverse Y-Axis Reverse Lock Head forward and Reverse Directions FIGURE 2-39. 990 APEX Operation Manual 2-37...
Page 72: About The Tool Config Tabs
About the Tool Config Tabs About the Tool Config Tabs Select the tab to go to this screen. Tool Config At this screen, specifications of the tool are entered and saved to the database. This information is valuable to compute and provide the most precise cut available. contains: Tool Config Screen •...
Page 73: To Unlock The Configuration
About the Tool Config Tabs To Unlock the Configuration The Lock function is an Option. Note: Select the Unlock Button. Enter Password in the Pop-Up win- dow. Click will change to a Unlock Button Lock Button. Tools can now be configured. Configure and the data.
Page 74: About The Tool Parameters
About the Tool Config Tabs Tool Enable and Disable FIGURE 2-40. About the Tool Parameters Table 2-16 on page 2-41 includes definitions of the tool configurations for the , and Router Drill Chisels Figure 2-41 below shows the configuration parameters of a router at the Router Configuration screen.
Page 75: Tool Config. Parameter Definitions
About the Tool Config Tabs Drill Config Screen FIGURE 2-42. Figure 2-43 below shows the configuration parameters of chisels at the Chisel Configuration screen. Chisel Config Screen FIGURE 2-43. Tool Config. Parameter Definitions Table 2-16 below shows the definitions of the parameters.
Page 76 About the Tool Config Tabs Router Tool Config Definitions TABLE 2-16. Parameter Definition Max Pocket Depth The deepest pocket that can be cut with this tool. Should be less than or equal to total length. Max Bite Per Lateral Pass How much material should be removed on each depth pass (Z).
Page 77: About The Tool Path Preview
About the Tool Path Preview About the Tool Path Preview Select the tab to display this screen. Tool Path Preview Test At this screen, an animated path of the tool-cutting sequence is displayed. This sequence can be essential if troubleshooting, calibrating, or checking the wear of a tool. Discrepancies can be viewed before cutting into a door or jamb, saving product and time.
Page 78 About the Tool Path Preview If needed, select the button located in the to focus on the Zoom to Fit Display Window tool cut. At the bottom of the page select the back arrow to start the cut from the beginning. Select the button to run the display of the cut.
Page 79: About The Selected Path
About the Tool Path Preview About the Selected Path Located at the left side of the screen, this section lists the in the . Select Feature Groups Door Job the desired cut to display the tool path. See Figure 2-45 below.
Page 80: About The Instructions Tab
About the Tool Path Preview Display Window Descriptions TABLE 2-17. Display Item Description Zoom to Fit Button Select to zoom to the cutting area. Located at the upper right of the screen. Legend A legend displays the color-code icon of each tool. Located at the upper right of the screen.
Page 81: About The Options Tab
About the Tool Path Preview About the Options Tab Set the actions of the tool path animation and the view of the display window. See Figure 2-48 below. Options Tab Screen FIGURE 2-48. Options Selection Descriptions TABLE 2-18. Display Item Description Show Routine Shapes Select the Check Box to turn ON an outline of the common shapes.
Page 82: About The Json Tab
About the Tool Path Preview About the Json Tab At the Json Tab, Code is displayed. See Figure 2-50 below. Json Json Tab FIGURE 2-50. 990 APEX Operation Manual 2-48...
Page 83: About The Status Screen
About the Status Screen About the Status Screen At this screen, real-time feedback during the operation of the machine can be viewed. The feed- back includes times, dates, and machine status. Status includes a if the assembly is in operation or a if not in operation.
Page 84: About The Log Screen
Green = Report is a non-issue Yellow = Warning If the machine issue can not be resolved, contact (1-800-553-5825). Have Kval Technical Support any error code that is displayed, ready to give the representative to aid in troubleshooting and Kval shorten downtime.
Page 85: Description Of The Light Tower
Description of the Light Tower Description of the Light Tower indicates the working status of the system. Highly visible indicator lights are Light Tower mounted on top of the A series of colors and flashing codes helps determine Main Electrical Panel. the machine error.
Page 86 Description of the Light Tower 990 APEX Operation Manual 2-52...
Page 87: Chapter 3 Calibration Of The Machine Line
Calibration of the Machine Line CHAPTER 3 This chapter describes steps to calibrate the machine. Chapter 3 at a Glance About Calibration ................. 3-2 About the 990-APEX Calibration Screen ..........3-3 How to Enter Calibration Data ............. 3-5 Starting the Calibration ................ 3-7 Tools Needed ..................
Page 88: About Calibration
Is the door or jamb true? Check for sawdust build-up, which may affect depth. recommends that a test door and jamb are run first and checked for specifi- Note: Kval cations before a full run is started. 990 APEX Operation Manual...
Page 89: About The 990-Apex Calibration Screen
About the 990-APEX Calibration Screen About the 990-APEX Calibration Screen contains a list of calibration adjustments. Select the located Calibration Screen 990-APEX Tab on the left hand side of the machine, then select the to jump to this menu. Enter...
Page 90: Unlock The Calibration (Option)
About the 990-APEX Calibration Screen Unlock the Calibration (Option) Access to the calibration is password protected. (Optional) Select the button Unlock At the pop-up, enter the password and select OK to continue. Password The calibration message will change from a red ''Calibration is Locked '' to a green Calibration is Unlocked”.
Page 91: How To Enter Calibration Data
If issues can not be resolved, contact (1-800-553-5825). Kval Technical Support Enter a Positive or Negative Number? Determine when to enter a positive of negative number by using the...
Page 92: About Restore Points
How to Enter Calibration Data Save Button: Select to store the calibration. The Save Button FIGURE 3-3. Below are general instructions to perform a calibration. See Figure 3-2 Figure 3-3 as a refer- ence for the process below. Check for deviations between the expected machining and the actual machining. Determine the offset.
Page 93: Starting The Calibration
Starting the Calibration Starting the Calibration The following set of processes verify the calibration of your machine. It is essential to follow the calibration in the steps listed here. If a step is Important: missed or not validated, other calibrations could be in error. Mechanical Calibrations To calibrate your machine, load to provide references to verify the machine.
Page 94: Tools Needed
Measuring Tape Calculator (Kval suggests to use the same calipers for all measurements for consistency) b. (Kval suggests to use same tape measure for all measurements for consistency) Calibration Door Jobs The table below shows the that are used to verify the calibrations.
Page 95: Step 1: About The Width Adjust Calibration
Step 1: About the Width Adjust Calibration Step 1: About the Width Adjust Calibration This calibration verifies that the width between the machine fences is in specification. No door machining is performed in this calibration. Note: ools Needed Item Description Door Job (Hinge) Door Job Title: Apex Calibration: Hinge Head Setup.
Page 96 Step 1: About the Width Adjust Calibration Enable at the screen. Auto Feed Main Control a. The width adjustment moves into position. Check the displayed above the button at the Position Number Width Adjust Main screen. This number is the width feedback value. See Figure 3-5 below.
Page 97: Step 2: About The Door Thickness Probe Calibration
Step 2: About the Door Thickness Probe Calibration Step 2: About the Door Thickness Probe Calibration There are two Thickness Probes located at the and the of the Lock Section side of A-Side B-Side the machine. The probes use a laser to measure the thickness. See “About the Door Thickness Modules”...
Page 98 Step 2: About the Door Thickness Probe Calibration Select to the tab at interface and type the word “ into the Status 990-APEX measured” field. Then press the button. This should give you three val- Name Filter Expand All ues.
Page 99: Step 3: About The A-Side Door Stop Calibration
Step 3: About the A-Side Door Stop Calibration Step 3: About the A-Side Door Stop Calibration is the reference for the top of a right hand door. This calibration fine tunes A-Side Door Stop the location of the stop in the X-Axis.
Page 100 Step 3: About the A-Side Door Stop Calibration Go to the screen in interface and type the word “ ” Status 990-APEX ASideDoorStop into the field. Then press the button. This should give you Name Filter Expand All the value.
Page 101: Step 4: About The Hinge Carriage Calibration
Step 4: About the Hinge Carriage Calibration Step 4: About the Hinge Carriage Calibration This process verifies that each is calibrated. The calibration fine- Hinge Carriage Hinge Carriage tunes the location of each in the Hinge Carriage X-Axis No door machining is performed in this calibration. Note: Tools Needed Item...
Page 102: Verifying And Adjusting The Hinge Carriage Calibration
Step 4: About the Hinge Carriage Calibration Verifying and Adjusting the Hinge Carriage Calibration Make sure previous steps are completed and the Apex Calibration: Hinge Head Setup is still downloaded. Door Job Load the test 8.0’ door into the machine and make sure go into posi- Hinge Carriages tion and the door is clamped.
Page 103: Step 5: About The Jamb Clamp Calibration
Step 5: About the Jamb Clamp Calibration Step 5: About the Jamb Clamp Calibration are step motor driven. This calibration adjusts the step motors for each Jamb Clamps Jamb Clamp No door machining is performed in this calibration. Note: Tools Needed Item Description Door Job (Hinge)
Page 104 Step 5: About the Jamb Clamp Calibration Adjust each calibration to meet the 1.0 inch measurement. Follow the Jamb Clamp steps in “How to Enter Calibration Data” on page 3-5. Figure 3-14 below shows the centering of the to the Jamb Clamps H-Blocks c.
Page 105: Step 6:About The Hinge Carriage Tool Calibrations
Suggested: Quantity of 2 or more - 8’0” x 1.375” Door (any width) OR: Quantity of 2 or more -6’8”x1.375” Door (any width) Calipers Kval recommends to use the same calipers for all measurements for consistency About the Hinge Calibration Shape...
Page 106: Verifying The Hinge Calibration Shapes
Step 6: About the Hinge Carriage Tool Calibrations Before calibrating or verifying, confirm that the data matches Important: “Tool Config” physical hardware for all tools loaded in the spindles. Select the Config and find the desired tool menu.Make sure the all the tool parameters match the installed tools including Tool Length Measure from the base of the tool in the collet to the tip of the tool.
Page 107 Step 6: About the Hinge Carriage Tool Calibrations X-Axis and Z-Axis: Use the edge of the as a reference and measure to H-Block each cut. Measure the depth of each cut. See Figure 3-17 below. Measurement Reference Value H-Block Edge to the Cutter Thru Pocket Edge 1.00”...
Page 108: Adjusting The Hinge Shape Calibrations
Tip: Tool Path Preview screen. Select the tab at the interface to view the tool Tool Path Preview 990-APEX paths. For more information about see “About the Tool Path Tool Path Preview Preview” on page 2-43. 990 APEX Operation Manual...
Page 109: Step 7: About The Hinge Chisels Calibration
Step 7: About the Hinge Chisels Calibration Step 7: About the Hinge Chisels Calibration This process verifies that the tools are calibrated. The table below lists the parame- Hinge Chisels ters that are verified. TABLE 3-6. Tools Calibration Chisels Corner locations Tools Needed Item Description...
Page 110: Performing The Hinge Tooling Calibrations
Step 7: About the Hinge Chisels Calibration Performing the Hinge Tooling Calibrations Verify the calibration of the tooling by following the procedure. If an eight foot door is not available, at the door job, remove Hinge #4 and Note: change the Door length to 6’-8”. Hinge # 4 will need to be adjusted with the top of the door at the B-Side Stop.
Page 111: Adjusting The Hinge Chisels Calibrations
Tip: Tool Path Preview screen. Select the tab at the interface to view the tool Tool Path Preview 990-APEX paths. For more information about see “About the Tool Path Tool Path Preview Preview” on page 2-43. 990 APEX Operation Manual...
Page 112: Step 8: About The B-Side Door Stop Calibration
Step 8: About the B-Side Door Stop Calibration Step 8: About the B-Side Door Stop Calibration This calibration verifies the location. B-Side Door Stop Tools Needed Item Description Door Job (Hinge) Door Job Title: Apex Calibration: Hinge Head Setup. Test Door Suggested: Quantity of 2 or more - 8’0”...
Page 113 Step 8: About the B-Side Door Stop Calibration Disable all hinges except Hinge 4 in the Door Job Add the door to the Queue. Measure the distance from the to the top edge of the cut. It should be Door Stop as shown in Figure 3-22 below.
Page 114: Step 9: About The Lock Head X-Axis Calibration
Step 9: About the Lock Head X-Axis Calibration Step 9: About the Lock Head X-Axis Calibration Verify the calibration by aligning the edge of the carriage to a door at Lock Head Carriage A-Side A-Side Door Stop No door machining is preformed in this calibration. Note: Tools Needed No tools needed...
Page 115: Step 10: About The Lock Edge Tools Calibration
Step 10: About the Lock Edge Tools Calibration Step 10: About the Lock Edge Tools Calibration This process verifies that each tool is calibrated. The table below lists the parameters Lock Edge that are verified. There are two parts to this calibration, 1. verifying the location of the shape and Note: 2.
Page 116: Performing The Lock Edge Tooling Calibrations
Step 10: About the Lock Edge Tools Calibration Performing the Lock Edge Tooling Calibrations Perform the calibration of the tooling by following this procedure. Before calibrating or verifying, confirm that the data matches Important: “Tool Config” physical hardware for all tools loaded in the spindles. Select the Config and find the desired tool menu.Make sure the all the tool parameters match the installed tools including...
Page 117: Adjusting The Lock Edge Calibration Shape Location
Step 10: About the Lock Edge Tools Calibration If the shape locations are out of specifications, go to "Adjusting the Lock Edge Cal- ibration Shape Location" next. If the shape locations are in specifications, skip the section below and verify the shape dimensions, go to "Verifying the Lock Edge Lock Dimensions"...
Page 118: Adjusting The Lock Edge Calibration
Step 10: About the Lock Edge Tools Calibration Y-Axis and Z-Axis: To verify the , measure the depth of each cut To verify Z-Axis the X-Axis, measure from the edge of the door to each bottom edge of the cuts.(Backset.) See the Figure below and the Table on the previous page for specifi- cations.
Page 119 Tip: Tool Path Preview screen. Select the tab at the interface to view the tool Tool Path Preview 990-APEX paths. For more information about see “About the Tool Path Tool Path Preview Preview” on page 2-43. 990 APEX Operation Manual...
Page 120: Step 11: About The Lock Face Tools Calibration
Step 11: About the Lock Face Tools Calibration Step 11: About the Lock Face Tools Calibration This process verifies that the are calibrated. The table below lists the parameters Lock Face Tools that are verified. Lock Tool Edge Parameters TABLE 3-8. Tools Calibration Router (Side A)
Page 121: Performing The Lock Face Tooling Calibrations
Step 11: About the Lock Face Tools Calibration Performing the Lock Face Tooling Calibrations Perform the calibration of the tooling by following the procedure. Before calibrating or verifying, confirm that the data matches Important: “Tool Config” physical hardware for all tools loaded in the spindles. Select the Config and find the desired tool menu.Make sure the all the tool parameters match the installed tools including...
Page 122: Adjusting The Lock Face Calibration
Tip: Tool Path Preview screen. Select the tab at the interface to view the tool Tool Path Preview 990-APEX paths. For more information about see “About the Tool Path Tool Path Preview Preview” on page 2-43. 990 APEX Operation Manual...
Page 123: Step 12: About The End Tools Calibration (Option)
Step 12: About the End Tools Calibration (Option) Step 12: About the End Tools Calibration (Option) This calibration adjusts the both End Tools Ball Catch The same is used for both spindles, the user changes the Note: Calibration Door Job hand of the door in the to perform the calibration cut.
Page 124: Performing The B-Side (Lh) End Tooling Calibration
Step 12: About the End Tools Calibration (Option) Performing the B-Side (LH) End Tooling Calibration Perform the calibration of the tooling by following the procedure below. The default door hand is left hand. Run this first. After running the this Note: Door Job , change the to a right hand door and rerun the door job.
Page 125: Verifying The B-Side (Lh) End Tooling Calibration
Step 12: About the End Tools Calibration (Option) Verifying the B-Side (LH) End Tooling Calibration X,Y, and Z-Axes Using the lock edge side of the door and (Left Hand Door/B-Side): the bottom face side of the door as references, measure the shape location. Measure the depth of the shape.
Page 126: Adjusting The End Tooling Calibration
Tip: Tool Path Preview screen. Select the tab at the interface to view the tool Tool Path Preview 990-APEX paths. For more information about see “About the Tool Path Tool Path Preview Preview” on page 2-43. 990 APEX Operation Manual...
Page 127: Chapter 4 Tour Of The 990-Apex
Hanging System. 990-APEX. pter 4 at a Glance Machine Terms ..................4-2 Overview of Machine ................4-4 About the Controls of the 990-APEX ............ 4-6 About Safety Controls ................4-9 About the Feed System ................ 4-12 About the Width Adjust .................
Page 128: Machine Terms
The door stop sets the door in the correct position for processing. Jamb Stop The jamb stop sets a reference for the jamb to be in the correct position for processing. It is located on the front section of the machine and is set manually by the operator. 990-APEX Operation Manual...
Page 129 Chisels Chisels are located in the Lock and Hinge Carriages. The chisels (Opt CH) square the corners on the hinge pockets and the lock plate. 1. Customer can change the operation/bits to meet their specifications. 990-APEX Operation Manual...
Page 130: Overview Of Machine
Side A Side B Electrical Panel Safety Scanner and Indicator Hopper Width System Six Shooter Belt Feed System Feed System Movable Side Fixed Side Local Machine Control Shooter Hydraulic Pump Identification of Key Assemblies of 990-APEX FIGURE 4-1. 990-APEX Operation Manual...
Page 131: 990-Apex With Rts Rotary Hoppers
6 Shooter Local Machine Control Feed System Feed System Movable Side Fixed Side 8 Shooter or Screw Delivery 6 Shooter 8 Shooter or Options 6 Shooter Identifications of Key Assemblies of a RTS 990-APEX Version FIGURE 4-2. 990-APEX Operation Manual...
Page 132: About The Controls Of The 990-Apex
About the Controls of the 990-APEX About the Controls of the 990-APEX Machine controls are described in this section. About the Operators Station is equipped with a touch screen and keyboard to operate the machine. The Operator’s Station station may include controls for other machines in the machine line.
Page 133: About Kvalcam
About the Controls of the 990-APEX About KvalCAM eases the programming process of hardware templates and door jobs, while also giving KvalCAM the customer complete control over tooling selection, calibration. Door Jobs can be stored to cen- tral database that can be shared across different machines and even different facilities.
Page 134: About The Local Machine Controls
About the Controls of the 990-APEX About the Local Machine Controls The local controls are located at the “B” Side of the machine for easy access. Figure 4-6 below for an example the Local Machine Controls. The controls include: Start Sequence 1 •...
Page 135: About Safety Controls
Learn all safety controls before operating the machine. Important: This machine is powerful. Kval has incorporated many sophisticated safety features to keep the operator safe around this machine. However, the operator should always be alert and aware of safety procedures when operating this machine.
Page 136: About Laser Safety Scanners And The Safety Status Indicator
Scanner location FIGURE 4-8. 1. It is important to note that objects left in the scanning area can also cause the Scanner to trip. Always keep a clean area in the Hinge cutting portion of the machine. 990-APEX Operation Manual 4-10...
Page 137: About Gates Latches
Gate layouts and gate locking systems may vary from machine to machine. For Note: example, some machines may have keyed, magnetic locking systems. The logi- cal safety operations are the same. Safety Sensor Door Latch Gate Locking System FIGURE 4-9. 990-APEX Operation Manual 4-11...
Page 138: About The Feed System
Fixed Side Feed Motor Steel Door Eye Feed Belts Mid Machine A-Side Outside Fence Eye A-Side Inside Fence Eye A- Stop Eye Door Edge Sense Eye A-Side Door Entering Machine Eye Feed System Components FIGURE 4-10. 990-APEX Operation Manual 4-12...
Page 139: Feed System Part Descriptions
This eye sends feed- back to the PLC that the door at the machine and alerts the previ- ous machine to stop the feeding process and let the 990-APEX take over. Door Edge Sense Eye The Door Edge Sense Eye is a photo sensor located on the “A”...
Page 140 1. On the Reverse Feed Option, the Side “A” and Side “B” may be either infeed or outfeed designated. 2. Motor Specifications maybe be found in the Electrical Print and in the Service Manual of the 990-APEX. 3. For information about the Width Adjust System, “About the Width Adjust”...
Page 141: About The Width Adjust
Width Adjust Connecting Axel Width Adjust Servo Motor Movable Fence Side B Side A Fixed Fence Chain Drive Side A Chain Drive Side B Width Adjust System FIGURE 4-11. 990-APEX Operation Manual 4-15...
Page 142: About The Door Thickness Modules
The laser emits the beam the top of the back fence to the door and uses this distance as a reference. Laser Module Laser Beam Active Laser Distance Reader FIGURE 4-13. 990-APEX Operation Manual 4-16...
Page 143: About The Clamping The Door
Door Stop The top of the door is normally located at the activated Note: Door Stop. Door Stop B Door Stop A Feed Belt Location of Door Stops FIGURE 4-14. 990-APEX Operation Manual 4-17...
Page 144: About Door Clamping
• 2 door clamps • 2 jamb clamps Figure 4-15 below shows the door clamps from the Front Section view of the machine. Front Section Door Clamps 2 Clamps per Jamb Swing Front Section Door Clamps FIGURE 4-15. 990-APEX Operation Manual 4-18...
Page 145: About Back Section Door Clamping
• 2 side clamps that act as a fence to secure the side of the door. (Designated A and Figure 4-16 below shows the down-clamps and the side clamps from the view. Back Section Down Clamps Side Clamp Down Clamps Side Clamp B Side Clamp A 10 Clamps Total Back Section Clamps FIGURE 4-16. 990-APEX Operation Manual 4-19...
Page 146: About The Jamb Shelf
Jamb in Machine FIGURE 4-17. Figure 4-18 below shows the and an inserted from the rear perspective of the Jamb Shelf Shelf Pin H-Block. Shelf Pin Jamb Shelf H-Block Rear View of Jamb Shelf FIGURE 4-18. 990-APEX Operation Manual 4-20...
Page 147: About Jamb Stops
FIGURE 4-19. About the Jamb Stop Figure 4-20 below shows a . The cylinder extends align the stop to the jamb. Jamb Stop Assembly Cylinder Pivot Arm Jamb Stop Turret Jamb Stop Jamb Stop Assembly FIGURE 4-20. 990-APEX Operation Manual 4-21...
Page 148: About The Jamb Clamps
2 Clamps per Jamb Swing Vertical Jamb Clamps FIGURE 4-21. Figure 4-22 below shows the from an inside of the machine view. Side Jamb Clamps Side Jamb Clamps 2 Clamps per Jamb Swing Horizontal Jamb Clamps FIGURE 4-22. 990-APEX Operation Manual 4-22...
Page 149: About The Jamb Swing
Figure 4-23 below shows the location of the on the machine. Jamb Swings See the for more specifications about the Note: 990-APEX Service Manual Jamb Swing System. Jamb Swing Locations Jamb Swing Locations FIGURE 4-23. Jamb Swing Part Identification Figure 4-24 below shows the from the front perspective.
Page 150: Jamb Swing Part Descriptions
Jamb Swing Stepper Motor System Part Identification Table 4-2 on page 4-24 for stepper motor system part descriptions. Timing Belt Stepper Motor To Belt Interfaces (X4) Timing Belt Stepper Motor Drives Belt Clamps Stepper Timing Belt System FIGURE 4-25. 990-APEX Operation Manual 4-24...
Page 151: Jamb Swing Stepper Motor System Descriptions
The basic functions of stepper motor drives are to generate signals from input data in order to move the motor axis. The drives converts the stepper motor command signals into the power necessary to energize the motor windings and drive the stepper motor system. 990-APEX Operation Manual 4-25...
Page 152: About The Hinge Carriage
• A third spindle is designated for pre-drilling any hole pattern from point to point. • Corner chisels to create corner squaring on the hinge and the jamb. Hinge Carriage Locations Hinge Carriage Locations FIGURE 4-26. 990-APEX Operation Manual 4-26...
Page 153: Hinge Carriage Part Locations
H-Block Hinge Tool Carriage Proximity Sensors Hinge Z-Axis Servo Motor Not all Sensors are shown, see the 990-APEX Service Manual for a full diagram Hinge Valve Bank Field Bus Not all Field Buses are shown, see the 990-...
Page 154 Hinge Carriage. Feedback to the Operator’s Station indicates the time to change the module. 1. Not a physical part of the Hinge Carriage, however, is an integral part of the hinge routing pocket process. 990-APEX Operation Manual 4-28...
Page 155: Hinge Tool Carriage Part Location
Operation chapter of this manual. All three spindles are 1.3 kW, have a maximum RPM of 24,000, and are fan Note: cooled See the for more specifications about the Note: 990-APEX Service Manual Tool Carriage parts. Tool Carriage Part Descriptions TABLE 4-5. Part Description...
Page 156 1. On all cylinders, hall effect sensors on each end of the cylinder trigger on the internal magnetic field within the cylinder to feedback rod position to the PLC. 990-APEX Operation Manual 4-30...
Page 157: About The Six/Eight Shooter System
Parking Locations Parking places for the screw shooters are located at each end of the machine.Each shooter must be secured in the designated parking place when not in use. 990-APEX Operation Manual 4-31...
Page 158: Six/Eight Shooter Part Identification
“Hinge Applicator Part Descriptions” on page 4-43. Quick Screw Change Option Z and Z1: Supplies a quick method to change screw types on the Eight and the Six Shooter. For more information,see “Quick Change Part Descriptions” on page 4-71. 990-APEX Operation Manual 4-32...
Page 159: About The Six/Eight Shooter Controls
Load/Un-Load Button Clear Screws Button Unclamp Button Reset Button Start Sequence Button Insert Screw Button Controls of the 6/8 Shooter FIGURE 4-31. Option: Quick Change Screw Drop ON/OFF Knuckle Hinge Switch Screw Drop Switch FIGURE 4-32. 990-APEX Operation Manual 4-33...
Page 160: Control Panel Part Descriptions
One of the uses for this function is to trou- bleshoot with out the screw delivery active. 1. Do not adjust air settings if not trained. Contact the your facilities machine specialist or contact Kval Technical Support. 990-APEX Operation Manual...
Page 161: About The Hopper
Six/ . If you think problems are being caused by the cylinders, Eight Shooter f or direction. please contact the Kval Technical Support Department Do not put magnetized screws in . Magne- Important: Hopper tized screws can cause sluggish response to screws getting stuck.
Page 162: Hopper Part Descriptions
Hopper Hopper Cylinders This organizes the screws and delivers them to the Screw Tracking Plate monitors the quantity of screws delivered to the Gate Assembly Screw Tracking Plate Assembly 990-APEX Operation Manual 4-36...
Page 163 Screw Pick-Off Start Sequence trol panel to activate the Slide Assembly to drop the screws into the Screw Delivery Tubes. Each tube has air injectors to speed the delivery To Index Fixture to the Screw Receiver Tubes 990-APEX Operation Manual 4-37...
Page 164: About The Rts Rotary Hopper
Change the text on the button to suit your production style, by holding the Tip: CTRL button down on the keyboard and selecting the Hopper button. Type the desired label in the pop-up box. Eight Shooter Buttons on the Interface FIGURE 4-35. 990-APEX Operation Manual 4-38...
Page 165: Rts Eight Shooter Option
RTS Eight Shooter Option Figure 4-36 below shows the option. Split deliver the screws to the jamb Eight Shooter Hoppers and the door. The Hoppers are labeled to identify them. RTS Eight Shooter Option FIGURE 4-36. 990-APEX Operation Manual 4-39...
Page 166: About The Driver Assembly
Forward Stop Limit Switch Reverse Stop Limit Switch Not shown. It is located on the other side of the Driver assembly parallel to the Forward Stop Limit Switch. Six/Eight Shooter and Gear Box Call-Outs FIGURE 4-37. 990-APEX Operation Manual 4-40...
Page 167: Driver Assembly Part Descriptions
These tubes receive the screws from the hopper by way of plastic tubes. Latch Arm Latches to the H- Block to secure in place. For a better view of the Latch Arm, see “About the Hinge Applicator” on page 4-42. 990-APEX Operation Manual 4-41...
Page 168: About The Hinge Applicator
Latch Arm Latch Arm Cylinder Hinge Applicator Parts FIGURE 4-38. Split Shells 8 Shooter Applicator Index Spacer (Opt) –Retracts to accept wide barrel hinges –Extends to accepts narrow barrel hinges Eight Shooter Hinge Applicator FIGURE 4-39. 990-APEX Operation Manual 4-42...
Page 169: Hinge Applicator Part Descriptions
If replacing parts in this assembly, use this figure as a guide for part installation. Screw Receiver Spring Split Shell Steel Ring Steel Ring Set Screw Rubber Ring Split Shell Stack-up FIGURE 4-40. 990-APEX Operation Manual 4-43...
Page 170: About The Lock Carriage
• Two ball-catch routers bore holes and route face plates on the Ball Catch Option: door top edge. Lock Carriage Location Lock Carriage Location FIGURE 4-41. 990-APEX Operation Manual 4-44...
Page 171: Lock Carriage Part Identification
• Y-Axis Servo Motor: Moves the Lock Carriage vertically. Lock Tool Carriage The Lock Tool Carriage contains face and edge drilling/routing: • Two door edge s pindles. • Four door edge corner chisels. • Two door face spindles. • (Option) Two Ball Catch spindles. 990-APEX Operation Manual 4-45...
Page 172: Lock Tool Tray Part Identification
Spindle Air Cylinders Chisels Cylinder Chisels Cylinder Edge Spindle Edge Spindle Small Large Face Spindle Face Spindle A–Side B–Side Chisels Chisels Ball Catch Spindle Ball Catch Spindle A–Side B–Side Lock Tool Carriage Part Identification FIGURE 4-43. 990-APEX Operation Manual 4-46...
Page 173: Tool Carriage System Part Descriptions
Note: Tool Carriage KvalCAM “About the Tool Config Tabs” on page 2-38 See the for more specifications about the Note: 990-APEX Service Manual Lock Tool parts. Carriage Tool Carriage Part Descriptions TABLE 4-13. Part Description...
Page 174: About The Electrical Panels
High Frequency Panel. For in depth electrical information, see the machine schematic. Note: Electrical Panel Overview Figure 4-44 below shows the Electrical Panels Air Conditioner Main High Frequency Power Box Locking System APEX Electrical Panels FIGURE 4-44. 990-APEX Operation Manual 4-48...
Page 175: Powering-Up The Electrical Panel
Figure 4-46 below shows the power down lever location Make sure area is safe. Follow the procedure to power down each individual machine. Move lever into the (Down) position. Move Lever Down Power Down FIGURE 4-46. 990-APEX Operation Manual 4-49...
Page 176: About Opening The Cabinet Doors
The spring trigger locks into position. • Turn the to the position and remove the key. Door Latch Key Lock Keyed Locking System Compress Spring Loaded Trigger to Turn Lever Electrical Panel Levers FIGURE 4-47. 990-APEX Operation Manual 4-50...
Page 177: About The Magnetic Safety Locking System
Each side of the has a magnetic locking mechanism installed. For operating direc- Electrical Panel tions, see “About Opening the Cabinet Doors” on page 4-50. Figure 4-48 below shows the mag- netic locking module. Magnetic Lock FIGURE 4-48. 990-APEX Operation Manual 4-51...
Page 178: About The Main Electrical Panel
(Programmable Logic Controller.) • Contains servo drives to interact with the servo motors. PLC Section PLC Terminals Analog Voltage Section Analog Terminals (24 VDC and 110 vac) Circuit Breaker Section Servo Drive Section Main Electrical Panel FIGURE 4-49. 990-APEX Operation Manual 4-52...
Page 179: Plc Section
The extension has a removable compact flash card from which the PLC boots. 40 Gb Fast Card, 3D flash, extended temperature range. PLC Power Supply Unit The power supply unit CX2100-0014 supplies power to the Embed- ded PLC system modules and the extension modules. 990-APEX Operation Manual 4-53...
Page 180: Analog Voltage Section
Refer to the labels in the cabinet and the electrical schematic for more informa- Note: tion. AC Volt Terminals 24 VDC Power Supplies DC Volt Terminals 120 vac E-Stop Relay 48 VDC Power Supplies Control Analog Voltage Section FIGURE 4-51. 990-APEX Operation Manual 4-54...
Page 181 Panel. AC Volt Analog Terminals Connections for AC voltages (110vac/120vac) in the Electrical Panel. E-Stop Relay Relay stops the connection when an E-Stop is initiated. 120 vac Control DC Volt Relay to control the AC voltages. 990-APEX Operation Manual 4-55...
Page 182: Circuit Breaker Section
The Power Distribution system takes incoming power and splits it into paths to supply different components in the panel. The PDR is a contactor. Contactors are designed to control and suppress the arc produced when interrupting heavy motor currents. 990-APEX Operation Manual 4-56...
Page 183: Servo Drive Sections
Fuse holders in-line with the Servo Drives. Pull down on top of the holder latch to access the fuse. Power Supply Module A power supply module that generates the DC-Link voltage (DC) for the power supply of the axis modules. 990-APEX Operation Manual 4-57...
Page 184 “About the Hinge Carriage” on page 4-26. 4. For locations of the Lock Carriage servo motors, see “About the Lock Carriage” on page 4-44. 5. For the location of the Width Adjust servo motor, see “About the Width Adjust” on page 4-15. 990-APEX Operation Manual 4-58...
Page 185: About The High Frequency Panel
High Frequency Panel: • Supplies voltages to the machine. • (Variable Frequency Drives) to interact with hinge and faceplate routers, width adjust motors, and feed motors. VFD Section –Circuit Breakers Transformer Section High Frequency Cabinet FIGURE 4-54. 990-APEX Operation Manual 4-59...
Page 186: Vfd Section
For more information, consult the cabinet and electrical labels. Note: –Busbar Circuit Breakers VFD’s –Busbar Circuit Breakers VFD’s VDF Section Descriptions FIGURE 4-55. 990-APEX Operation Manual 4-60...
Page 187 Figure 4-56 below show the locations and descriptions of the com- ponents in the section. Transformer For more information, consult the cabinet and electrical labels. Note: –Busbar Control Circuit Breakers Transformer VFDs Transformer Section FIGURE 4-56. 990-APEX Operation Manual 4-61...
Page 188 Circuit breakers of various current values protect components on the machine and in the cabinet. Busbars add an interface to incoming power leads. 1. Verify VFD operation by using the electrical schematic and the labels in the electrical cabinet. 990-APEX Operation Manual 4-62...
Page 189: About Network Topography
FIGURE 4-57. Hinge Section EtherCAT Boxes Figure 4-58 below shows the location of the EtherCAT Boxes that interconnect with the Hinge . Each contains the boxes. Carriages Carriage Head EtherCAT Boxes Hinge Section EtherCAT Locations FIGURE 4-58. 990-APEX Operation Manual 4-63...
Page 190: Shooter Ethercat Boxes
As well as an EtherCAT input/output Box, EtherCAT Stepper Motor drivers are located at the end of “B” side of the machine. Figure 4-60 below shows the locations of the EtherCAT Boxes. Stepper Motors Stepper Motor Drives Back Section EtherCAT Locations FIGURE 4-60. 990-APEX Operation Manual 4-64...
Page 191: About The Pneumatic System
Distributes air to various parts of the machine. If after the Lubricator, nor- mally diverted to Valve Banks that need oiled air. Pressure Switch Low Pressure Switch used to protect the Carriage Heads from crashing during operation. 1. See the Service Manual for the lubricator adjustment directions. 990-APEX Operation Manual 4-65...
Page 192: About The Valve Banks
• L/A Out-Bus Out State • RUN-Operation State • PWR- Power Supply for Control • PWR(V)-Power Supply for Solenoid Valve Solenoid 5-Port Base Mounted Double Internal Pilot Non-Locking Push Solenoid Valve With Light, Flow Rate, 4 Ways, and 2 Positions. 990-APEX Operation Manual 4-66...
Page 193: Pneumatic System Overview
Main Air Supply 233-00-204 Door Position Door Position 233-00-201 Lock Section 233-00-207-L 233-00-206 Shooter Lock Carriage Frame “B” High Pressure Jamb 233-00-203 233-00-200 Jamb Clamp Head 1 – Head 4 233-00-207-R Shooter Valve Back Locations FIGURE 4-63. 990-APEX Operation Manual 4-67...
Page 194 • Jamb/door Clamp #4 Off • Jamb Swing Clamp • Jamb Clamp 0/3 Degree • Split Jamb Extend (Optional) • Split Jamb Fire (Optional) Note: Air is also diverted from this Valve Bank to Split Jamb Air Gun source. (Option) 990-APEX Operation Manual 4-68...
Page 195 • Door Open/close • Hook Latch / Screwdriver In • Casting Up /down (Option) High Pressure Jamb This is a discrete solenoid to drive assembles for the Jamb/Door Clamps. Pressure can range from 35 psi to 60 psi. 990-APEX Operation Manual 4-69...
Page 196: Option S: Quick Change Knuckle Assembly
After completing the process, flip switch again to extend the index spacer to accept narrow barrel hinges. Toggle Switch –Activates solenoid –Deactivates solenoid Solenoid Index Spacer –Retracts to accept wide barrel hinges –Extends to accepts narrow barrel hinges Option S Configuration FIGURE 4-64. 990-APEX Operation Manual 4-70...
Page 197: Option Z And Z1: Quick Screw Change
Quick Change Dump Gate The gate opens to dump the screws into the funnel. After the screws are emptied, the gate closes Quick Change Funnel The funnel leads to a container to catch the dumped screws. 990-APEX Operation Manual 4-71...
Page 198: Quick Change Process
. This will Assembly Hopper cycle one more time to clear the screws from the slides. Press the on the panel or at the interface. Reset Button Six/Eight Shooter KvalCAM Fill the with new screws. Hopper 990-APEX Operation Manual 4-72...
Page 199: Option N: Weather Strip Brackets
Weatherstrip retaining brackets; provide brackets to hold weatherstripping back and eliminate the risk of router coming into contact with weatherstripping. Figure 4-66 below shows the components of Option N: Weather Strip Brackets. Protective Weather Strip Bracket H-Block Hinge Carriage Weather Strip Bracket FIGURE 4-66. 990-APEX Operation Manual 4-73...
Page 200: Option O: Air Blow Off
Sensors turn off the air after the door exits the machine. Figure 4-67 below shows components in the Circuit Breaker. Side B Air Blow off Assembly Option O: Air Blow -Off Location FIGURE 4-67. 990-APEX Operation Manual 4-74...
Page 201: Option Sj: Securing Split Jambs
Staple Gun Assembly. Refer to Manufacturers Manuals for specific information about the staple gun. Note: Fire Solenoid Air Supply Staple Output Trigger Safety Interlock Staple Cartridge Staple Gun Assembly FIGURE 4-69. 990-APEX Operation Manual 4-75...
Page 202: Split Jamb Process
If not already done so, load the male split jamb into the female slot of the jamb Load jamb assembly into machine. The staple gun will not fire unless the enable button is activated on the Operator Note: Screen and the safety switches are activated by the male split jamb. 990-APEX Operation Manual 4-76...
Page 204 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...

Kval 990-APEX Operation Manual

Chapter 1 Introduction to the 990-APEX System

Chapter 2 Operation of the 990-APEX

Chapter 3 Calibration of the Machine Line

Chapter 4 Tour of the 990-APEX

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