Kval 994-X, Operation Manual

Page 1: ...Innovation Quality Honesty Includes Option RTS 994 X Pre Hanging Door System 994 X Pre Hanging Door System Operation Manual Published 1 19 22 ...

Page 2: ... Windows is a registered trademark of Microsoft Corporation All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated Contacting KVAL Customer Service For further information about this manual or other Kval Incorpo rated products contact the Cus...

Page 3: ...erience with our product that is the manual the machinery the software etc What was easy or difficult to use or to learn If you could change something about the design what would it be Please email your comments and suggestions for improve ment to userexperience kvalinc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information above Thank ...

Page 4: ...KVAL 994 X Operation Manual ...

Page 5: ...t Tagout Power 1 12 Lockout Tagout Air Supply 1 13 Start Maintenance 1 13 Post Maintenance Steps 1 13 Zero Energy to Start Up 1 14 Getting Help from KVAL 1 16 Kval Return and Warranty Policy 1 17 Send the Item 1 17 Acceptance of Return 1 17 Refund Turnaround Time 1 17 Kval Errors 1 17 Customer Errors 1 18 Shipper Errors 1 18 Warranty Replacement Parts 1 18 How to Download the Service Application 1...

Page 6: ...r Screen Rotary 2 21 About the Manual Operation Screens 2 22 About the Diagnostic Screen 2 26 Option SB About the CNC Back Section Operator Screens 2 27 Option SB Main Menu Screen 2 27 Option SB Lock Calibration Screen 2 28 Option SB Manual Screen 2 29 Option AR HQ2 2 30 Chapter 3 Calibration of 994 X About Calibration 3 2 Before you Calibrate 3 2 Flow Chart of Calibration 3 3 About the KVAL Calib...

Page 7: ... 4 994 X with Standard Hoppers 4 4 994 X with RTS Hoppers 4 5 About the RTS Rotary Hopper 4 6 Basic Operation of the RTS 4 7 Operator Controls 4 8 Operator s Station 4 8 Machine Control 4 9 Door Jamb Foot Pedal 4 10 About the In Feed Section 4 11 Door Stops 4 12 Setting Jamb Stop and Jamb Height 4 12 About the Front Section 4 13 About the Hinge Carriage 4 14 Option CR Counter Rotate Router 4 15 Op...

Page 8: ... Option IL Left Hand Right Hand Door Indicator 4 30 About the Electrical Panels 4 31 Main Electrical Panel 4 31 High Frequency Panel 4 32 Description of the Six Light Panel 4 33 About Sensors 4 34 Option Checking Screw Delivery 4 35 Option ND Auto Narrow Door 4 36 Option N Weather Strip Brackets 4 37 Option SJ Securing Split Jambs 4 38 Option Checking Screw Delivery 4 39 Addendum 7 6 Door Stop 4 4...

Page 9: ...ription and a table of available options page 1 2 Safety IMPORTANT safety information is described in this section page 1 7 Zero Energy to Start Up Procedure to power up your machine for the first time page 1 14 Getting Help from KVAL This section describes the method to contact the KVAL service center for help The section includes how to get information from the specifi cation plate tor provide t...

Page 10: ... to drill all common hinge patterns automatically Additionally the use of servo motors allows you to machine both 1 4 and 5 8 radius corners without changing out tooling Hinges may be attached manually or with the optional Six Shooter to install 3 1 2 X 3 1 2 hinges or the optional Eight Shooter for attaching 4 X 4 hinges while the door and jamb remain clamped in position Door to door productivity...

Page 11: ...r KVAL Sales and Service department Option Title Description Option A Six Shooter Gun for 3 1 2 X 3 1 2 To attach 3 1 2 X 3 1 2 hinges to the door and jamb No 9 by 3 4 long flat head screws are automatically sorted and fed six at a time to the screw gun Operator manually places the hinge onto the magnetic indexing fix ture and then rolls and pivots the Six Shooter into an H block at each hinge loc...

Page 12: ...ing four extra routers to the hinge detailing section with left hand rota tion As hinge pockets are routed the left hand rotating routing tool is used to minimize chipping of the door face or jamb edge Option E Two Stage Drilling Allows changeover for two different face bore sizes with a selection on the control panel Customer to specify 1 1 2 or 1 5 8 for dead bolt face bore when ordering Standar...

Page 13: ...pocket locations Hinge location specifications need to be submitted in order to determine if they can be accommodated with the 994 X Option Z Screw Changing Hopper for Six Shooter Screw changing hopper for changing screw colors Option Z1 Quick Change Hopper for Eight Shooter Screw changing hopper for Eight Shooter allows for rapid change of screw colors Quick Change Knuckle Hinge Switch located on...

Page 14: ...ace Descriptions of how to power machine line and operator interface user screens Chapter 3 Calibration Description of the Calibration routines Chapter 4 Tour of the Machine Descriptions of the mechanical assemblies on the machine Chapter Title Description Chapter 1 System IT Brief description of Computer and PLC in the Machine Chapter 2 Maintenance Maintenance steps for the machine line Chapter 3...

Page 15: ...ed or illegible There are three types of warning labels or decals 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 Safety Guidelines In addition to the caution and warning labels affixed to this machine fol...

Page 16: ...n Never perform any maintenance unless machine is at zero state Never clean the machine while it is running Never walk away from the machine while it is running When the Machine is ON The compressed air system connected to this machine should have a three way air valve for shut off and pressure relief All cylinders on machine are under high pressure and can be very dangerous when activated Before ...

Page 17: ...ed at different locations Before performing any repairs or mainte nance lockout and tagout must be installed at all locations All maintenance and repairs to electrical circuitry should only be per formed by a qualified electrician Still has power in OFF position Electrical Prior to performing any maintenance repairs cleaning or when clearing jammed debris you must disconnect tag out or lock out th...

Page 18: ...t If you believe any part or operation of this machine is in violation of any health or safety regulation STOP pro duction It is your responsibility to immediately protect your employees against any such hazard Additional detailed safety guidelines are included in the operating instructions of this manual KVAL will be pleased to review with you any questions you may have regarding the safe operati...

Page 19: ...and tag on each disconnect Only each operator may remove their own lock and tag Important When many people are all working on the same machine you will need a multiple lockout device such as the one shown here Follow the P R O P E R lockout rule of thumb P Process shutdown R Recognize energy type electrical pneumatic mechanical etc O OFF Shut off all power sources and isolating devices P Place loc...

Page 20: ...supply and pressure spring tension weight shifts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shutdown 3 Obtain locks keys and tags from your employer s lockout center 4 Turn off machine See Chapter 2 for power down and power up procedures 5 Turn the disconnect switches on ALL electrical and frequency panels to the OFF position Then push the red tab to pop it...

Page 21: ...re completely removed and that all guards and safety devices are installed 10 Before removing the locks and tags the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re energized 11 The lock and tag can now be removed only by the person s who placed them and the machine can be re energized 12 The tags must be destroyed and ...

Page 22: ... when energy is restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is started Perform Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the personnel alarm before starting the equipment If your operation is more complex your company s compr...

Page 23: ...key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers 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 ...

Page 24: ...rd the serial number 3 phase volts electrical print number and air print number 2 Contact our customer support team In the U S and Canada call 800 553 5825 or fax 707 762 0485 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 Air...

Page 25: ...RMA _______________ Send the Item Return the item to this address Kval Inc RMA ______ Kval Parts 825 Petaluma Blvd South Petaluma CA 94952 USA Acceptance of Return We can only accept items for a return if they are still in their original packaging and in undam aged resalable condition Returns are accepted within 45 days of purchase and with an RMA number issued by Kval Inc Returns after 45 days of...

Page 26: ... 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 of or defect in the products regardless of when the failure or defect arises and whether a claim however described is based upon contract warranty indemni...

Page 27: ... 2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Google we...

Page 28: ...ogram is ready to allow technicians to access machine computer 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 Indicator Green indicates there is a good connec tion to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support ...

Page 29: ...How to Download the Service Application 1 21 KVAL 994 X Operation Manual Page Intentionally Left Blank ...

Page 30: ...ow my company s safety procedures I have read and understand these guidelines Machine Safety Concerns I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the electrica...

Page 31: ...ended to read Operator s Tour on page 4 2 to understand the functions of the machine Chapter 2 at a Glance Section Name Summary Page Quick Start A summary of the steps to machine a door page 2 3 Powering Operations Descriptions of power up power down homing and emergency stops page 2 5 Description of the User Interface Screen Descriptions of the Operator Interface Screens page 2 8 ...

Page 32: ...door it is highly recommended to read Operator s Tour on page 4 2 to understand the functions of the machine The 994 X will Machine a hinge pocket on a door and jamb for up to 4 hinges Head Assembly Drill pilot holes for the hinge screws Head Assembly Apply up to 4 hinges Six Shooter or and Eight Shooter Attach the hinges with screws Six Shooter or and Eight Shooter Cut a lock lock plate and Lock ...

Page 33: ...nt of the machine turn the Door switch to RH Right Hand or LH Left Hand Door Turn the Feed Mode switch to ON Auto Feed Preset Buttons Left Hand or Right Hand Auto Feed ON Start Sequence Feed in a door from the Door Feeder In Auto mode the Door will Auto Clamp Insert a Jamb aligning it firmly on all the jamb ledges Press the Jamb firmly against the jamb stop Holding the jamb in place with hands in ...

Page 34: ...e back section routers lock bore and bolt drill Slide the Six Shooter over and position it into the H Block using the Ryertex guides 1 Press the Start Sequence button to move the Six Shooter into position and drop the screws The Six Shooter will snap into place 2 When fully seated press the Insert Screw Button to attach the six screws 3 Press the Reset switch to raise the Six Shooter out of the hi...

Page 35: ...p up is displayed on the user screen if an E Stop is pressed The pop up will indicate which E Stop has been activated 3 Make sure the electrical disconnect in the electrical cabinet is turned to the ON posi tion 4 Switch the green Control Circuit switch to the ON position It should light up 5 Push the green Start Machine button to boot up the machine Note Boot up may take 2 to 3 minutes Control Ci...

Page 36: ...t Down System at the Main Screen to close oper ator interface program and shut down the operating sys tem Note Make sure Windows is shut down completely before turning off the machine Hard drive or data may be damaged if not turned off in this order 2 Switch the green Control Circuit switch to the OFF posi tion 3 KVAL also recommends that you turn the disconnect switch on the electrical cabinet to...

Page 37: ...ound the machine Note Depending on the machine option E Stop buttons may be located at various locations The E Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment When an E Stop switch is activated power to the machine is killed The machine responds in the same way if you press the STOP button on the operator s station ...

Page 38: ... Note Locked out parameters may vary due to customer design criteria Machine Feed Back At the top and at the bottom right hand cor ner of all user screens is status feedback information The information generated is as follows 1 General Machine Status 2 Front Section Status 3 Back Section Status 4 Current Servo Positions Note Use this information to isolate issues if having problems with the machin...

Page 39: ...reen Door Parameters Preset Buttons Door Spec Hinge Spec Back Section Screw Hopper Door Controls Feed Controls Clamp Controls Width Controls Machine Controls Stop Door Seq Reset Machine Shut Down System Home Machine Manual Screen Width Adjust Door Stop Clamp Skip Hinges Feed Control Burn Chipout Test Mode Exit Application Jog Lock Location Hinge Servo Jog Manual Jog Jog Hinge Carriage 1 Jog Hinge ...

Page 40: ...Pre Drill Template Lock Location 6 8 RH LH 7 0 RH LH 8 0 RH LH Feed Sys timing Jamb Shelf Height Plate Fast Timers Plate Slow Timers Diagnostics Log screen Total Door Count Daily Door Count See About the Diagnostic Screen on page 2 26 See About the Machine Calibration Screen on page 2 15 Chisels Upper Left Chisel Upper Right Chisel Lower Left Chisel Lower Right Chisel ...

Page 41: ...le on this screen Options and customer preferences can change the interface buttons For samples of Option inter faces see the following Option SB see Option SB About the CNC Back Section Operator Screens on page 2 27 AR HQ Rotate Table see Option AR HQ2 on page 2 30 Split Jamb Option see Option SJ Securing Split Jambs on page 4 38 Option V Narrow Doors see About the Back Section on page 4 25 FIGUR...

Page 42: ...e machine to the start position before homing Always press the Home Machine button after Reset Machine Stop Door Sequence Button This button stops the door in the process Shut Down System Button This button shuts down the computer Use this button as part of the shutdown pro cess See How to Power Down the 994 X on page 2 6 Preset Selection Button Group Pressing a preset button calls one of twelve p...

Page 43: ...e adjust Choose pre drill patterns Enable or disable Hinge 2 Select and change hinge parameters Enable or disable through hinge cuts True Hinge Override Click to display an input box to enter the true dimensions of hinge stock The machine will adjust to deliver a cut mirroring the input data You can select Pre Drill buttons to down load pre drill parameters or turn off this func tion To set Pre Dr...

Page 44: ...out Feed Through Option Press Feed Through to toggle the feed through on or off In feed through mode the door will pass through the machine without processing Auto Width Press Auto Width to toggle the auto width on or off In auto width mode the machine will automatically set the width adjust system for optimum clamping Auto Unclamping Press Auto Unclamping to toggle auto unclamping on or off The a...

Page 45: ...een you can perform cal ibration of the lock location and lock bore location change machine timing and speeds and posi tion the jamb shelf on the front section FIGURE 2 2 Setup Menu Main Cal Machine Calibration screen See About the Machine Calibration Screen on page 2 15 Setup Hinge 1 4 screens See About the Setup Hinges 1 4 Screens on page 2 17 Pre Drill Setup screen See About the Pre Drill Scree...

Page 46: ...nd and right hand doors This is the original reference LH Moves the lock location for left hand doors only RH Moves the lock location for right hand doors only Feed System Timing Adjustments Infeed Stop This is distance the clamped door is located after the after infeed eye Out feed Stop This is the distance the clamped door is located after the before out feed eye Fast Lock Plate Timing Vertical ...

Page 47: ... for head locations Setup Hinge 1 Setup Hinge 2 Setup Hinge 3 Setup Hinge 4 FIGURE 2 3 Hinge Setup Menu 1 of 3 Slow Lock Plate Timing Vertical The amount of time in seconds to give the vertical movement of the lock plate when in Slow Plate mode Horizontal The amount of time in seconds to give the horizontal movement of the lock plate when in Slow Plate mode Counter Rotate Route Chisels ...

Page 48: ...ese adjustments move the point to point drill in the X Y or Z direction Router Adjustments These adjustments move routers in the X Y or Z direction The radius of the router cut also may be adjusted Use this menu to compensate for minor changes in tooling during calibration Option CR Chisel Adjustments These adjustments move Chisels in the X Y and Z direction Use this menu to compensate for minor c...

Page 49: ...ion Manual About the Pre Drill Screen At this screen you can adjust and store up to five pre drill screw patterns in memory At the Setup menu select the Predrill Setup button FIGURE 2 4 Pre Drill Screen Name the Template Enter Drill Hole Loca tions ...

Page 50: ...r image of the parameters entered This allows for less time entering data and keeps precision drilling patterns The number 0 entered in both X and Y are equal to no drill Important Never enter a negative number in the Y parameter The pre drill will try to drill off the door into the Delrin FIGURE 2 5 Pre Drill Samples X Zero Point Y Zero Point Sample of 4 Hinge Dimensions X Zero Point Y Zero Point...

Page 51: ...Screen The rotary hopper stand RTS can also be adjusted Type unique names for each Hopper for identification pur poses All Hoppers Calibrate all hoppers as a set Hopper 1 through 4 Calibrate each Hopper individually Hints A positive number moves the Hopper in the Clockwise direction For more information about using the calibration boxes See Enter a Positive or Negative Num ber on page 3 7 ...

Page 52: ...About the Manual Operation Screens At 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 FIGURE 2 6 Manual Operation Screen FIGURE 2 7 Jog Carriage screen ...

Page 53: ...ivated Door Stop Press the Stop button to extend or retract the appropriate door stop Clamp Press Clamp to activate the cylinders that clamp the door Feed Reverse Press and hold the Reverse button reverse the feed of the door To stop the feed release the button Forward Press and hold the Forward button to move the door feed forward To stop the feed release the button Normal Speed Press and hold th...

Page 54: ... used to mimic the narrow door mode sensor If sensor is damaged press this button to feed narrow doors into the machine Press the Manual Air Injection to deliver a burst of air to the drop location to free any stuck screws or push a screw through Burn Chipout and Recover Narrow Door Use this menu if a new Chipout Block is installed on the lock section or the hinge if applicable sec tion Press the ...

Page 55: ...ft or Right Press and hold buttons to jog the hinge carriage location left or right To stop release the button Y Axis Up or Down Press and hold buttons to jog the hinge carriage location up or down To stop release the button Z Axis Out or in Press and hold buttons to jog the hinge carriage location in or out To stop release the button Speed Select the white box and enter the speed of the carriage ...

Page 56: ...issue cannot be resolved call KVAL Inc 1 800 553 5825 Have the error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten downtime The Diagnostic Screen keeps track of the all the doors processed on the machine The quantity is displayed in the Total Door Count box To keep track of daily production the quantity of doors produced in a day is displ...

Page 57: ...s section details the added features to the operator screens Note To read about all menu choices see Description of User Interface Screens on page 2 8 Option SB Main Menu Screen The following is added to the Main Screen in the CNC Back Section option Square Plate Some SB options have a Toggle to turn the square plate cut ting routine ON or OFF Lock Plate Adjust Lock Plate to the X Y and Z specific...

Page 58: ...tion of the 994 X The following screen is added in the CNC Back Section option Lock Location See Lock Location Adjustments on page 2 16 Lock Carriage Calibrates the Back Section Carriage in the X Y and Z direction Zero and three degree X and Y are calibrated separately Router These adjustments move router of the back section in the X Y or Z direction The radius of the router cut also may be adjust...

Page 59: ...t easy to change tools on the lock section head The buttons are located in the Manual screen Use the two buttons in tandem Option SB Lock Access Button with Access Tools OFF The Lock Plate will move to a position for easy access Lock Access Button with Access Tools ON Moves the Lock Plate out further if more room is needed to access tooling ...

Page 60: ...ble AR HQ2 In this case AR HQ2 controls and menu but ton are located on the Main Screen Note For information on 994 X with an AR HQ option see the AR HQ2 Operation and Service Manual This Manual is included with the Document Package Control the direction of the Door after pro cessing by the 994 X ...

Page 61: ... to calibrate page 3 2 About the Calibration Routine Specifications of the Calibration Routine page 3 4 Run the Calibration Routine Details on running a calibration reference for the Front page 3 6 Check and Adjust Front Section Calibrations Details on using the calibration screens to adjust he Front section tools page 3 7 Check and Adjust Back Section Calibrations Details calibration the Back sec...

Page 62: ...cutting tools Using this function will allow the operator observe any major issues during the machine cycle without damaging tooling or product See About the Manual Operation Screens on page 2 22 Before you start calibration check for the following common issues and ask yourself these ques tions 1 Is the loaded setup correct for the current cut 2 Are the machine stops set up correctly 3 When did t...

Page 63: ...About Calibration 3 3 KVAL 994 X Operation Manual Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the 994 X FIGURE 3 1 Calibration Process Flowchart ...

Page 64: ...t for inaccuracies The front end assemblies that use the calibration routine are as follows 1 Hinge Carriage 2 Router Standard 3 Option CR Counter Rotate Router to eliminate chipouts 4 Option CH Chisels to square the cut 5 Pre Drill FIGURE 3 2 Location of Assemblies Pre Drill Drills pilot holes for insertion of screws on the jamb and the door Router Routs the hinge pocket on the jamb and the door ...

Page 65: ... steps to machine the slot see Run the Calibration Routine on page 3 6 The Calibration slot dimensions and position will vary with the diameter of the drills and the door width For information on making adjustments see Check Specifications of the Front Sec tion on page 3 7 Dimensions of a Calibration Cut Run the calibration routine from the Main Screen and verify the router and drill calibration b...

Page 66: ...ce choose the following below 1 Choose Door Height Thickness 2 Choose Door Length 3 Disables Hinge 2 of the hinges leaving one hinge enabled Load the Door and Start the Cut 1 Load the test door into the in feed of the 994 X 2 Verify the setup and check for machine is safe to run 3 Press the Start button to begin the process Enable Calibration At the Menu list on the Hinge Spec Group NOTE If Calibr...

Page 67: ...er by using your Left Hand Use the cut on the door as a reference Hold out the left hand with the first finger pointed at the door second fin ger and thumb at right angle to each other The first finger represents the positive direction 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 Y X Axis Positive mov...

Page 68: ... below the parameter The Base display box keeps a running total of data entered to help keep track of the changes The Combine with Base button stores data in memory and should be used at first to set a reference and at final to store data See Check Specifications of the Front Section on page 3 7 for information on direction of servo motors FIGURE 3 5 Sample of an Adjustment Menu Title of assembly ...

Page 69: ...e right enter a negative number 6 If there is a number in the box under X Axis select the Combine with Base button to set a reference 7 Once this number is added to the base double select the box that has 0 000 A calcu lator will be displayed Enter the offset in this box 8 If it needs to go in the negative direction select the negative symbol 9 Select the check mark to confirm this number and exit...

Page 70: ... two Refer to the example located below 4 Next what way does the slot need to move To move up enter a positive number To move down enter a negative number 6 If there is a number in the box under Y Axis select the Combine with Base button to set a reference 7 Once this number is added to the base double select the box that has 0 000 A calcu lator will be displayed Enter the offset in this box 8 Sel...

Page 71: ...he Calibration Routine on page 3 6 2 Measure the depths of the Router and Pre Drill 4 If the depth is too deep enter a negative number of the difference of the measured and the desired depth 5 If the depth is too shallow enter a positive number of the difference of the measured and the desired depth 6 Rerun tests until the correct depth is achieved Enter a positive number to move the Carriage Up E...

Page 72: ...bine with Base 4 Enter calculations FIGURE 3 8 Router Calibration Menu 5 Repeat until cut is centered 6 Select the Combine with Base button to finish 7 Repeat until cut is centered 8 Click Combine with Base to finish X To move the cut to the right enter a positive value To move the cut to the left enter a negative number Y To move the cut to up enter a positive value To move the cut to the down en...

Page 73: ...rill 1 Run the Calibration Routine See Run the Calibration Routine on page 3 6 2 Check measure and calculate specifications of Pre Drill cut 3 To set a new reference go to the calibration menu and select Combine with Base 4 Enter calculations X To move the cut to the right enter a positive value To move the cut to the left enter a negative number Y To move the cut to up enter a positive value To m...

Page 74: ... centered 6 Select Combine with Base to finish X To move the cut to the right enter a positive value To move the cut to the left enter a negative number Y To move the cut to up enter a positive value To move the cut to the down enter a negative number Z To increase the depth enter a positive value To decrease the depth enter a negative value ...

Page 75: ...that the H block is setup in the correct location 3 Run the hinge 4 After the hinge run is finished check all four corners of the hinge to see if the chis els are in the correct location 5 If the corners of the hinge are out of specification continue the process on the next page Select button to gain access to the Chisel Calibration menu Adjusting the Chisels 1 Identify the corner or comers to be ...

Page 76: ... axis box b If the chisel is too deep enter it as a negative number c If the chisel is too shallow enter it as a positive number d Repeat until chisel position is correct 6 Click the Combine with Base button to combine the two numbers to create refer ence a Take the caliper measurement and enter it into the X axis box b If the chisel needs to move to the left enter it as a negative number c If the...

Page 77: ...tion Calibration Lock Bore Location r t FIGURE 3 10 Path to Calibration screen Back Section Lock Location Calibration FIGURE 3 11 Reference Door Lock To start run a known good lock cut at a standard location on a Right Hand or Left Hand door Once the lock cut is completed check the distance from the top of the door to the center of the lock Note the measurement value and compare to specification I...

Page 78: ...f the settings are in Extend Time adjust the Slow Lock Plate Timing FIGURE 3 12 Fast and Slow Lock Plate Timing Menu Vertical 1 Select the size door 6 8 7 0 8 0 2 Select Right Hand or Left Hand depending on the door run through process 3 Under Base select the Combine with Base but ton 4 Enter a positive number to move the lock cut to the right Enter a negative number to move the lock cut to the le...

Page 79: ...r number This number is in seconds If there is a delay before the vertical moves enter a smaller number in this box Continue entering numbers until timing is matched Option SB CNC Back Section Calibration This section describes calibration screens for the optional CNC back section Lock Carriage Calibrates the Back Section Carriage in the X Y and Z direction Zero and Three degree X and Y are calibr...

Page 80: ...ay be adjusted Chisel Calibration Back Section These adjustments move Chisels in the X Y and Z direction Use this to compensate for minor changes in tooling during calibration Run a known good lock bore at a standard location on a Right Hand or Left Hand door Once the lock bore is completed check the distance from the top of the door to the center of the bore hole Note the measurement value Positi...

Page 81: ...nual Enter a positive or negative number to move the tool in the desired direction X Y Z Positive number moves tools in nega tive number moves tools out Positive Number Negative Number Positive Number Negative Number Upper Right Upper Left Lower Left Lower Right ...

Page 82: ...Calibration of the Back Section KVAL 994 X Operation Manual 3 22 ...

Page 83: ... the machine page 4 2 Machine Components Description of Common Machine Terms page 4 3 Machine Overview Assembly Identification of the machine page 4 4 Operator Controls Descriptions of the machine Controls page 4 8 In Feed Description of the In Feed page 4 11 Front Section About Hinge Carriages Six Shooter and Hopper page 4 13 Back Section About the Lock Section Options page 4 25 Out Feed Descript...

Page 84: ...s options to adapt to many factory processes This manual describes many of the popu lar options For a full list of options see Available Options on page 1 3 The 994 X will Machine a hinge pocket on a door and jamb for up to 4 hinges Head Assembly Drill pilot holes for the hinge screws Head Assembly Apply up to 4 hinges Six Shooter or and Eight Shooter Attach the hinges with screws Six Shooter or a...

Page 85: ...ock edge of the door Lock Bore The lock bore is located on the back section It drills a lock hole on the face of the door Pre drills The pre drills are located in the Carriage Heads They pre drill screw holes for hinge screw application on the door and jamb Chisels Opt CH Chisels are located in the Carriage Heads and the back section The chisels square the corners on the hinge pockets and the lock...

Page 86: ...of Key Assemblies of 994 X Hopper See About the Hopper on page 4 20 In Feed See About the In Feed Section on page 4 11 Front Section Six Shooter See About the Six Eight Shooter Controls on page 4 19 Hinge Carriage 1 See About the Hinge Carriage on page 4 14 Hinge Carriage 2 Hinge Carriage 3 Back Section See About the Back Section on page 4 25 Out Feed See About the Out Feed Sec tion on page 4 29 E...

Page 87: ...and each Hopper can be filled with different type colored screws for dif ferent applications FIGURE 4 14 RTS Hoppers RTS Delivers the screws to selected Hinge Applicators Rotates in 90 degree increments Screws are delivered by way of air driven feed hoses Air Hoses Pressurized air delivers the screws through hoses to the machine Hopper On board Hopper is removed and replaced with the RTS ...

Page 88: ...ected for processing at the machine operator s interface If an operation error occurs the operator can clear the screws select correct screw hopper and re feed screws If the operator does not want an auto feed to occur it can be deactivated to allow the screw feed to occur manually To learn more about the Hopper see About the Hopper on page 4 20 FIGURE 4 15 RTS Assembly Identification Air Tank Air...

Page 89: ...e dropped into the tubes and air injected Screws are sent to the machine To 994 X Cylinders X2 Extends drop plate to be flush with Hopper to allow clean drop of screws Retracts when screws are dropped Repeats cycle for next Hopper Gauge and Adjustment Adjusts the air pressure to the air tubes Typical is PSI is listed on the machine ...

Page 90: ...tation also includes management functions such as daily and lifetime totals See Description of User Interface Screens on page 2 8 and See Quick Start on page 2 3 for more information FIGURE 4 17 Operator s Stations with touch Screen Interface The Operator s Station can be placed at different locations as per customer requirements Above are examples of an Operator s Station attached to the machine ...

Page 91: ...rols with Disable Auto Feed FIGURE 4 19 Machine Controls without Disable Auto Feed EmergencyStop If Safety issues occur press this button LH RH Door Select a Right Hand or Left Hand Door Disable Auto Feed Stops Door Feeding Through Feed Mode Chose Auto OFF or instant feed thru Start Sequence Starts the sequence of machining a door Start Sequence Starts the sequence of machining a door Disable Auto...

Page 92: ... the jamb in both the auto and manual modes Door Clamp Push the Door Clamp foot pedal clamp and then un clamps the door after each cycle of operation when the machine is in the manual mode Press once to clamp and press again to un clamp Jamb Clamps Two Clamps per Head Manually clamped Door Clamps Two Clamps per Head Can be Auto clamped and Manually clamped Jamb Ledge Jamb Stop Door Clamps Jamb Led...

Page 93: ... FIGURE 4 21 Key Assemblies on the In Feed Section In Feed System Door the enters machine here Sensors triggered and width is adjusted to door Hydraulic Tank for Eight Shooter Sets and lifts the Eight Shooter out of the hinge pocket Feed Motor Drives the Door through the machine Door Stops Weather Strip Brackets Opt N Keeps weather strip on jamb away from machining process Not shown See Option N W...

Page 94: ...and Bottom of Door Right Hand Top of Door Left Hand Bottom of Door Right Hand Top Door Left Hand 8 0 6 8 Some options may have a separate 7 0 stop in between the 8 0 and 6 8 stops Some options use the 6 8 stop as a reference for the 7 0 door 6 8 8 0 Add Spacers to the Jamb Shelf to change the height when processing different types of jambs Spacers are located at the Operator s Station To match the...

Page 95: ...door support Machine Control Hinge Carriages 1 through 4 FIGURE 4 23 View of Front Section Hinge Carriage 1 Hinge Carriage 2 Hinge Carriage 3 Hinge Carriage 4 Six Shooter Opt Z Quick Change Machine Control Eight Shooter Opt K Narrow Door Support Opt V Supports Doors under 16 0 for either Hinge or Lock Side Standard Pre Drill Router Opt CR adds CR Router Opt CH adds Chisels 4 corners ...

Page 96: ...or more information see Option CH Added Chisels on page 4 16 Standard Hinge routing sections are completely servo controlled for pocket height width and depth Each standard hinge routing section is equipped with two 1 1 2 HP High Fre quency spindle motors one for routing and one for pre drilling on both the door and jamb Opt CR adds another spindle motor for a Counter Rotate Router Servo motors al...

Page 97: ...ipping during hinge routing This option eliminates the chip out blocks by adding four extra routers to the hinge detailing section with left hand rota tion As hinge pockets are routed the left hand rotating routing tool is used to minimize chipping of the door face or jamb edge FIGURE 4 24 Hinge Carriage Parts with added Counter Rotate Router Option CR Pre Drill Counter Rotate Router Standard Rout...

Page 98: ...ption adds chisels to each head The chisel assemblies have an upper and lower chisel to square off the jamb and door pockets FIGURE 4 25 Hinge Carriage Parts with added Chisels Opt CH and Counter Rotate Router Opt CR Pre Drill Standard Router Left Chisel Right Chisel Counter Rotate Router ...

Page 99: ...six shooter 3 The Six Eight Shooter is mounted on an overhead track that is precisely aligned to ensure the hinge is properly position into the pocket at each hinge location 4 The operator a places a hinge to the magnetic indexing fixture b rolls the Six Eight Shooter over to the hinge location and pivots it into the H block c drives all six screws into the door and jamb d press the Reset switch t...

Page 100: ...attaches a 4X4 hinge and has two Hoppers to deliver screws FIGURE 4 27 Eight Shooter Parts Eight Shooter Six Shooter The Six Shooter attaches three screws to the jamb and three screws to the door Hoppers Supplies screws to Jamb and Door Indexing Fixture Magnetic Aligns screws and attaches the hinge to the door and jamb The Eight shooter attaches four screws to the jamb and four to the door Eight S...

Page 101: ... door either from a foot pedal or a Shooter mounted mushroom button Start Sequence The start sequence drops the Six Shooter into the pocket while starting motor for hydraulics It also drops the screws down aided with air injection to speed the screw feed process Hopper Slide Valve The hopper slide valve provides the operator a remote air shut off that controls air flow to the screw hopper to aid i...

Page 102: ...f the Six Shooter If you think problems are being caused by the cylinders please contact the KVAL Service Department for direction FIGURE 4 29 Hopper and Frame Interface Important Do not put Magnetized Screws in Hopper Magne tized screws can cause sluggish response to screws getting stuck Hopper plates could get magnetized and will have to be demagnetized with a degausser Hopper Quick Change Dump ...

Page 103: ...To start the quick change process 1 Park the Six Shooter 2 Press the Load Unload button on the Six Shooter panel The back section of the Hopper will cycle upward once to shift all the screws from the back door to clear screws between the back door of the hopper and the slides 3 Once the Hopper is in the up position the door will open and the Hopper will cycle down quickly to throw the surplus of s...

Page 104: ...ctory set to align hinge Screw Receiver Tubes These tubes receive the screws from the hopper by way of plastic tubes Latch Arm Latches to the H Block to secure in place Latch Arm Cylinder Moves latch arm in and out of position Hydraulic Motor Gearbox Geared to drive 6 screws simultane ously Chucks Holds six screws aligned to the Door and the Jamb Hinge Applicator Location to attach Hinge Turret to...

Page 105: ...s approximately 1 second A switch that is located on the Hinge Applicator triggers a solenoid to retract Space is then provided for a wide spring hinge Solenoid Retracts to provide space for a wide spring knuckle hinge Hinge Applicator Switch to trigger solenoid To Use this Function Flip the switch to activate the Solenoid Place the wide knuckle hinge into the Hinge Appli cator See Quick Start on ...

Page 106: ... mounted on an overhead track The track and the Six Eight Shooter are precisely aligned to ensure the hinge is properly positioned into the pocket at each hinge location FIGURE 4 31 Over Head Track Eight Shooter Opt K Keeps the Six Shooter in park and allows move ment down the machine Six Shooter Keeps the Eight Shooter in park and allows movement down the machine ...

Page 107: ...r Cylin ders on back section Feed Belt Feeds Door through Machine Lock Bore Motor and Drill Drills locks holes on the face of the door Ball Catch Motor and Drill Opt BC Drills ball catch top edge Out Feed on LH Door Ball Catch Motor and Drill Opt BC Drills ball catch on top edge In Feed on RH Door Chip Out Location Servo Motor Lock Section Self Centering X Axis Centers the Bolt drill in the X axis...

Page 108: ...ual 4 26 Back View of Rear Section Bolt Drill Extend and Retract Cylinder Face Plate Motor and Bit Routs face plate Bolt Drill Motor Machines lock plate on the side of the door Lock Bore Limit Switches Deep Shallow Retracted Lock Bore Oil Reservoir ...

Page 109: ...router and chisels complete with square lock face plates The Back section can machine a face plate at both 0 and 3 degree cuts Bolt Drill Motor Machines lock plate on the side of the door Ball Screw Left Lock Plate Chisel Cylinder Squares the edge of the lock plate Right Lock Plate Chisel Cylinder Squares the edge of the lock plate Z Axis Servo Motor Back Section Valve Bank Y Axis Servo Motor X Ax...

Page 110: ...d doors drive in ball catches When selected the proper drill automatically pivots in to drill into the top of the door Note Minimum door width for drilling is 18 0 Ball Catch Motor and Drill Drills ball catch top edge Out Feed on LH Door Ball Catch Motor and Drill Drills ball catch top edge In Feed on RH Door Ball Catch Cylinder Moves motor assembly to 8 0 or 6 8 door posi tion ...

Page 111: ...URE 4 32 Key Assemblies on the Out Feed Section Main Machine Air Drop Air Blow Off Opt O Blows off dust from the door as it Feeds Out Out Feed Door is fed to next stage Six Shooter RH LH Door Indicator Opt IL As the door exits a signal desig nates if door is Right Hand or Left Hand Hydraulic Tank for Six Shooter Sets and Lifts Six Shooter out of Hinge pocket ...

Page 112: ...n the Out Feed end of the 994 X that can be seen by the 700 C Assembly Table Operator The light will be on when the door in the 994 X is being machined as a right hand door and off for a left hand door Compressed air is directed at the door face as it exits the Out Feed Incoming Right Hand Door The indicator will be red if a Right Hand door is exiting the machine It will be off if the door is a Le...

Page 113: ...anel Figure 4 33 below is an overview of the location of assemblies in the panels Main Electrical Panel The Main Electrical Panel Supplies voltages to the machine Contains the PLC Programmable Logic Controller Contains servo drives to interact with the servo motors Axis and Lock Location in the front and back sections FIGURE 4 33 Overview of the Main Electrical Panel Main Electrical Panel Power Su...

Page 114: ...rs and feed motors FIGURE 4 34 Overview of the High Frequency Panel Contactors Thermal Overload and Control Transformer Lock Bore Motor Bolt Drill Motor Six Shooter screw Driver In Feed Ball Catch Opt BC Out Feed Ball Catch Opt BC Eight Shooter Screw Driver Opt K 110 V 24 V Terminals High Voltage Section Input Output Terminals VFD Section Hinges 1 4 Face Plate Router Feed Motor Width Adjust Pre Dr...

Page 115: ...4 X Operation Manual Description of the Six Light Panel The six lights on this panel indicate the status of the Commander III system The Sequence that the lights activate is as follows 1 Control Power 2 Overload Relay 3 E Stop 4 Stop 5 Start 6 24VDC ...

Page 116: ...If an assembly is in between the two sensors the machine will not operate One Package The Proximity Sensor detects metallic objects without touching them An inductive proximity sensor consists of a coil and ferrite core arrangement an oscillator and detector circuit and a solid state output The ferrite core and oscillator create a field generating out the front of the sensor When a metal object en...

Page 117: ... not pass by the sensors a red light located on the six shooter will turn on A popup dialog box will be displayed on the interface screen identifying the error tubes Investi gate and repair After screws are cleared continue with process Screw Delivery Sensors Ferro sensors located on each tube Fail Indicator Light If a screw is not delivered to the index of the six shooter this light will turn on ...

Page 118: ...In Feed of the machine After sensing the door a narrow door fence is engaged and adjusts to the doors width Note Lock functions are not available in the narrow door setting Standard Door Sensors Narrow Door Sensors The width of the door is com pared to the Standard Sen sor inputs to activate Narrow Door Fence Pneumatic Controls for Narrow Door ...

Page 119: ...94 X Operation Manual Option N Weather Strip Brackets A protective bar across top of H block keeps the strip up and away from the routers Protective Bar Keeps Jamb weather stripping from inter fering with the machining pro cess Carriage H Block ...

Page 120: ... This valve is interlocked with a safety switch to dis able the staple guns unless there is a jamb clamped in the machine Staple Guns For full process information See Quick Start on page 2 3 To Use this Function 1 Enable by selecting the Split Jamb Stapler enable dis able button 2 If not already done so load the male split jamb into the female slot of the jamb 3 Load jamb assembly into machine 4 D...

Page 121: ... not pass by the sensors a red light located on the six shooter will turn on A popup dialog box will be displayed on the interface screen identifying the error tubes Investi gate and repair After screws are cleared continue with process Screw Delivery Sensors Ferro sensors located on each tube Fail Indicator Light If a screw is not delivered to the index of the six shooter this light will turn on ...

Page 122: ...ton The machine will move the Jamb and Door Stop assemblies to the corresponding positions The figure below shows the location of the stops and an inset photo of positions of a right hand door setting The left hand door settings are located at the Out Feed of the Machine and are the mirror image of the right hand door settings Left Hand Door Stops The positioning is the mirror image of the Right H...

Page 123: ...al Note A machine with this option cannot run the ball catch process at the 7 6 loca tion See the Error Message below When the popup is closed the ball catch automatically turns off Calibration Screen For full descriptions of the screen choices see About Calibration on page 3 2 in the 994 X Oper ation Manual For this option the calibration routine includes the 7 6 Lock Location ...

Page 124: ...KVAL 994 X Operation Manual 4 42 ...

Page 125: ...der of steps 3 9 combine with base how to use 3 8 contact information 1 2 control transformer switch power up 2 5 2 6 customer service 1 2 D diagnostic screen description 2 26 door spec group description 2 13 E electrical panels description 4 31 emergency shutdown description 2 7 F feed system timing description 2 16 front section key assemblies 4 14 front section status feedback 2 8 H high freque...

Page 126: ... preset selection description 2 12 R remote operation setting up machine for 1 19 reset machine button description user interface 2 12 right hand door selecting 2 3 router calibration steps 3 12 S safety guidelines 1 7 Safety Sign Off Sheet Safety Concerns 1 22 sensors types 4 34 voltage levels 4 34 servo drives location in main electrical panel 4 32 servo positions feedback 2 8 setup hinges group...

Page 127: ...Index Kval 994 X Y Y axis calibration hinges 3 10 illustration of calibration 3 11 Z zero energy start up clean up 1 14 inspect 1 14 ...

Page 128: ...Index Kval 994 X ...

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Page 130: ...partment Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL Phone and Fax In the U S and Canada call 800 553 5825 or fax 707 762 0485 Outside the U S and Canada call 707 762 7367 or fax 707 762 0485 Email service kvalinc com http www kvalinc com ...