Kval Commander 3 User manual

Brand: Kval

Model: Commander 3

Type: User manual

Innovation, Quality & Honesty

Commander III Door System

With KvalCAM®

Commander III Service Manual

Service Manual

Published: December 21, 2022

KVAL Commander III Service Manual

Proprietary Notice

This manual is confidential and contains proprietary information and intellectual property of Kval

Inc., and is to be used solely by Customer as an operating manual for Kval Inc. machines. Neither

this manual nor any of the information contained herein may be reproduced or disclosed under

any circumstances without the express written permission of Kval Inc. For authorization to copy

this information, please call Kval Technical Support at (800) 553-5825 or fax (707) 762-0485.

Manual Name: Commander III Door System Service Manual

Manual Revision: 202-MV100.2, 202-MV101.0, 202-MV101.1

Commander III is a trademark of Kval Incorporated.

KvalCAM® is a registered trademark of Kval Incorporated.

Beckhoff®, TwinCAT®, and EtherCat® are registered trademarks and are licensed by Beckhoff

Automation GmbH

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

For further information about this manual or other Kval Incorporated products, please contact us.

Mailing address:

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

Phone and Fax:

call: (800) 553-5825

fax: (707) 762-0485

General Office Business Hours

Mon-Thu:6:00 AM - 4:00 PM PST

Fri: 6:00 AM - 3:30 PM PST

Parts

site at the “Contact Us” page.

email: pa[email protected]

KVAL Commander III Service 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: [email protected]

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.

email: [email protected]

Sales Support

For machinery information, specifications, and quotes. Call, email, contact us on our website at

the “Contact Us” page.

email: [email protected]

Kval Website

Learn about Kval, order parts, get information on our array of machines (including new machine

releases), learn about our machine software solutions, download machine documentation, view

videos of our machines in action, contact all the departments.

http://www.kvalinc.com

KVAL Commander III Service Manual

NOTICE OF OWNERSHIP OF KVALCAM SOFTWARE AND LIMITED LICENSE TO

USE

READ THIS NOTICE CAREFULLY BEFORE USING THE KVALCAM SOFTWARE WHICH OPERATES

KVAL MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED

LICENSE TO USE THE KVALCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.

BY USING THE KVALCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED

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 KVAL Machinery operated by the KVALCAM Software are the “Licensee”.

The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM

Software” and further defined herein) which are used in the operation of the KVAL Machinery are licensed, not sold,

to you for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to

you. Licensor retains all ownership of the KvalCAM Software.

Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with KVAL, Inc. The

ALCAM Software is protected by copyright laws and treaties. Title and related rights in the content generated

through the KVALCAM Software are also the property of the Licensor and are protected by applicable law.

Definitions.

a.“KVALCAM Software” means the KVALCAM computer application installed in the KVAL

Machinery and written documentation and materials provided to you, as well as any revisions or

updates of such computer application and documentation.

b.“Install” means storing of the KVALCAM Software in the computer component of the KVAL

Machinery.

c.“Use” means executing the KVALCAM Software for purpose of operating the KVAL

Machinery and use of the documentation for properly operating KVALCAM Software.

2. Grant of License.

a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the KVAL-

CAM Software upon payment of all amounts due for the purchase of the related KVAL Machin-

ery.

b.Licensee will make no copies of the KVALCAM Software or alter the KVALCAM Software

in any way. Title to the KVALCAM Software will remain vested in Licensor, and nothing in this

License will give or convey any right, title or interest therein to Licensee except as a licensee.

c.Licensee agrees that it will use the KVALCAM Software or related documentation directly or

indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License

set forth herein.

d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or

disassemble the KVALCAM Software.

e.This License will terminate automatically if Licensee fails to comply with the limitations

described above.

Table of Contents

Commander III

Chapter 1 Introduction to the Commander III

Chapter 1 at a Glance.............................................................. 1-1

Overview of the Commander III System .................................. 1-2

KvalCAM and the Commander III.........................................................1-2

Standard Features................................................................................1-2

Additional Features...............................................................................1-3

Table of Options...................................................................................1-4

About this Manual.................................................................................1-5

Operation Manual .................................................................................1-5

Service Manual.....................................................................................1-5

KvalCAM Reference Manual ................................................................1-6

Safety First!.............................................................................. 1-7

Safety Sheet Sign-Off Sheet.................................................................1-7

Safety Terminology of Labels................................................................1-7

Safety Guidelines..................................................................................1-7

Lockout-Tagout Guidelines ...................................................... 1-11

Follow the P-R-O-P-E-R lockout rule of thumb...................................1-11

Lockout Tagout Procedure....................................................... 1-12

Pre-Steps Before Lockout Tagout.......................................................1-12

Lockout 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

Zero-Energy State to Start-Up to Operating State..............................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

Safety Sign-Off Sheet .............................................................. 1-20

A Note to the Operator:.......................................................................1-20

Commander III

Table of Contents

Chapter 2 System IT Administration

System IT Administration ......................................................... 2-2

About the Commander III Computer.....................................................2-2

Connections on the PLC.......................................................................2-2

About Remote Connection to KVAL Service............................ 2-3

Network Diagram..................................................................................2-3

Chapter 3 Maintenance of the Commander III

Maintenance Schedule ............................................................ 3-2

300 Cycle Maintenance Steps ................................................. 3-4

Clean, Clean, Clean!.............................................................................3-4

600 Cycle Maintenance Steps ................................................. 3-5

Check Air Gauges and Inspect Water Traps.........................................3-5

Inspect Tooling......................................................................................3-5

Empty Dust Collection Units .................................................................3-6

3,000 Cycle Maintenance Steps .............................................. 3-7

Inspect Feed Belts (If Applicable) .........................................................3-7

Inspect all Photo Eyes ..........................................................................3-7

Inspect Limit Switches ..........................................................................3-7

Inspect Airlines......................................................................................3-8

Refill Lubricators (If Applicable) ............................................................3-8

Grease Ball Screw Bearings.................................................................3-9

Clean Bearing Shafts............................................................................3-9

12,000 Cycle Maintenance Steps............................................ 3-10

Inspect Chains for Proper Tension......................................................3-10

Inspect Air Cylinders ...........................................................................3-10

Inspect Hydraulic Lines.......................................................................3-10

Inspect Ball Rail Shafts and Ball Screws............................................3-11

Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........3-11

72,000 Cycle Maintenance Steps............................................ 3-12

Inspect Nuts and Bolts........................................................................3-12

Check Door Feeding Transition ..........................................................3-12

Electrical .............................................................................................3-12

Computer Backup...............................................................................3-13

Wash Filter and Lubricator Bowls .......................................................3-13

Maintenance NO-GOES .......................................................... 3-14

Lubrication Schedule ............................................................... 3-15

Typical Lucubration Kit........................................................................3-15

Table of Contents

Commander III

Lubrication Requirements........................................................ 3-16

Pillow Block Bearing Housings ...........................................................3-16

Flange Bearing Housings ...................................................................3-17

Ball Rail Bearing .................................................................................3-17

About Taper Bearings .........................................................................3-18

Tapered Bearing Housings .................................................................3-18

Ball Screw Nut ....................................................................................3-19

Ball Screw Drive Assembly .................................................................3-19

Pulley and Idler Shafts........................................................................3-20

About Grease Locations for the Machine ................................ 3-21

Servo Motor Drive Assembly Grease Locations ...................... 3-22

Frame Servo Grease Locations..........................................................3-23

Recommended Tools ..........................................................................3-23

Front Section Servo Assemblies.........................................................3-24

Recommended Tools ..........................................................................3-24

Cutter Head Grease Locations ............................................... 3-25

Recommended Tools ..........................................................................3-25

Cutting Head Base Grease Locations ................................................3-25

Cutting Head Tools Grease Locations ................................................3-26

Recommended Tools ..........................................................................3-26

Back Section Grease Points .................................................... 3-27

Recommended Tools ..........................................................................3-27

Grease Location on the Frame (Feed System) ....................... 3-28

Recommended Tools ..........................................................................3-28

Air Input with Lubrication ........................................................ 3-29

Adjusting the Air Line Lubricator ........................................................3-29

Priming the Air Line Lubricator............................................................3-30

Air Line Without Lubricator .................................................................3-30

Identifying Cutting Tools........................................................... 3-31

Tool Information for the Hinge Carriage..............................................3-31

Tool Information for the Lock Carriage................................................3-32

Replacing Bits in the Front Section ......................................... 3-33

How to Access to Bit Assemblies........................................................3-34

Remove and Replace the Router or Pre-Drill Bits ..............................3-34

Remove and Replace the Chisels ......................................................3-36

Replacing Tooling in the Back Section..................................... 3-37

Changing the Bore Drill.......................................................................3-37

Changing the Bolt Drill........................................................................3-38

Changing the Face Plate Drill.............................................................3-38

Commander III

Table of Contents

Chipout Block Replacement .................................................... 3-39

Tools ...................................................................................................3-39

How to Replace the Back Section Chipout Block ...............................3-39

How to Burn in the Chipout.................................................................3-40

Option W: Replacing Function Drill Assembly ......................... 3-41

Collet Torque Values................................................................ 3-42

Addition Collet Torque Values.............................................................3-43

Chapter 4 Troubleshooting the Commander III

Get Live Technical Help ........................................................................4-1

About Motion Control ............................................................... 4-2

Sequencing:..........................................................................................4-2

Point to Point: .......................................................................................4-2

Incremental:..........................................................................................4-2

Basic Control Circuit .............................................................................4-3

About a Typical Contactor Control ........................................... 4-4

About Contactor Troubleshooting .........................................................4-5

About Typical VFD Motor Drive Control................................... 4-6

About the VFD ......................................................................................4-7

About VFD Troubleshooting..................................................................4-8

Error Checking on the Variable Frequency Drives................................4-8

Using the Reset Buttons.......................................................................4-8

About a Typical Pneumatic Circuit ........................................... 4-9

Typical Pneumatic Assembly ..............................................................4-10

About the Coil (Solenoid)....................................................................4-10

About Cylinder Operation ...................................................................4-11

How the Pneumatic System Works ....................................................4-11

Extend Process...................................................................................4-11

Retract Process ..................................................................................4-12

Important Notice about Adjusting Cylinder Speed ..............................4-14

Adjusting Cylinder Extend Speed .......................................................4-14

Adjusting Cylinder Retraction Speed .................................................4-14

About Switches and Sensors................................................... 4-15

Using Sensors to Trouble Shoot .........................................................4-16

Troubleshooting Electrical Problems ....................................... 4-17

If the Power Stops During Normal Operation .....................................4-17

Description of the Light Tower ................................................ 4-19

Network System Overview....................................................... 4-20

Table of Contents

Commander III

Connections to Servo Drives ..............................................................4-20

Connections to VFD’s (High Freq Panel)............................................4-20

1-1

CHAPTER 1 Introduction to the Commander III

This chapter provides an overview of the Kval Commander III System and important safety infor-

mation to follow when operating the machine.

Chapter 1 at a Glance

The following information is available in this chapter

TABLE 1-1. Summary of Chapter

Section Name Summary Page

Overview of the

Commander III

System

This section provides an overview of the Commander III.

It includes a general description and a table of available

options

page 1-2

Safety First! IMPORTANT safety information is described in this sec-

tion

page 1-7

Zero-Energy to Start-

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 specification plate tor provide to

Kval, service center hours, and return procedures

page 1-16

Safety Sign-Off

Sheet

A record to track operators that are trained on the

machine.

page 1-20

Overview of the Commander III System

KVAL Commander III Service Manual

1-2

Overview of the Commander III System

The Commander III redefines door and jamb machining flexibility, bridging both residential and

commercial markets. Leveraging our revolutionary KvalCAM® software and Beckhoff hardware,

combined with 6-axis movement, the Commander III provides on-going return for facilities need-

ing to increase capacity and processing capability.

KvalCAM, proprietary door-machinery software, provides auto G-Code generation, complete

machine-line integration, and an intelligent scalable database spanning unlimited KvalCAM

machine lines and even facilities.

Auto G-Code generation enables engineers or operators to easily create template files for a wide

variety of hardware by shape, dimension, and location. Eradicating the need for sophisticated pro-

gramming, customers can increase product offering, inventory turnover, and expand market share

while reducing overhead cost.

Machine-line integration is accomplished by one central control system (KvalCAM) recognizing

each machine’s individual capability within the line and simultaneously assigning tasks to each

piece of equipment from one job or template file. As an end user this simulates a “single machine”

with the output and productivity gains of utilizing multiple machines. Template files can be cre-

ated remotely i.e engineering department, and sent to the machine-line queue for the operator to

select. Additionally, machine can be fed by way of the KvalCAM Barcode Mapper application.

KvalCAM and the Commander III

• Allows effortless creation and processing of new door-hardware templates i.e con-

cealed hinges

• Can process an array of strike and hinge jamb hardware with CNC capability using

front section.

• Mirror functionality allows doors to be processed right or left hand while maintain-

ing sill leading always; never need to rotate for door machining.

• Complete integration with other KvalCAM machines

• -Up to date with Kval’s latest superior technology; continuous updates available as

R&D continues.

*Barcode capable with KvalCAM Barcode Mapper purchase

Standard Features

•Hinge Head – dual spindle routers with counter rotation for clean entry and exit at

hinge corners (eliminates traditional chip-outs), programmable point to point drill

for screw pilot holes, and corner square chisels for door and jamb. Full X, Y and Z

axis programming is combined with precision ball screws and servo motors. Auto

tilt between a three degree door edge and jamb clamped in the square H blocks so

both can be processed simultaneously, as well as auto detect for jamb only and door

only processing without wasted motions.

•Hinge Centers – no collar bars - automatic adjustment with precision encoder sys-

tem combined with a servo motor drive and position lock. The traditional chain and

Overview of the Commander III System

1-3

KVAL Commander III Service Manual

torque limiter is now a ball screw so an operator can fasten the first hinge after the

hinge head shifts to the second hinge location. A couple of manual adjustments for

H blocks and jamb clamps are still necessary, but a pointer and setup mode reduce

this to under two minutes and eliminates errors.

•Lock Locations – fully automatic positioning for lock locations from the door top,

and up to three locks can processed on one door. Program allows operator to change

between two auto-selections for lock-hole backsets (2-3/8” or 2-3/4”) and Face Plate

widths (1” or 1-1/8”). Zero or three degree bevel can be accommodated with

mechanical adjustment via turret. Up to 5” backset and up to 1-1/4” x 12” face plates

can be manually adjusted. Option FC adds corner squaring and full CNC control of

face plate routing.

•Door Reference Stops – fully automatic positioning of off-feed door stop to match

door length and hinge off-set with a ball screw and servo motor. The infeed stop is

fixed and is the zero reference for all other settings.

•KvalCAM and Beckhoff Control System – integrated components including all Beck-

hoff servo motor and drives. This makes remote support and program updates easier

than ever before. A connection to the internet is required for remote support from

Kval, which can remain physically disconnected except when needed. Software is

pre-installed to monitor all machine functions from our offices in Petaluma when

required.

Additional Features

• Efficient hinge and lock dust take-off connections.

• Auto width adjust to match incoming door widths 18" - 48", or 12" to 48" with

Option ND.

• Door feed system with parallel non-marking belts and heavy duty AC drive for

smooth speed transitions at door reference stops.

• 5 HP lock bore, and 3 HP latch bore with precision Acuflex collets and nuts.

• Auto door clamp.

• Air blow-off to clean the face as the door off-feeds.

• Door hand indicator light to speed processing in a companion 700-C Door Framer.

Overview of the Commander III System

KVAL Commander III Service Manual

1-4

Table of Options

Option Title Description

Option

Reverse Feeds Facing the hinge routing head, the normal direction is

left to right. This option reverses the feed direction to

feed from right to left.

Option

Architectural Door Package Adds a barcode scanner and processing for architec-

tural doors up 2-1/4” thick., which integrates with the

machine’s industrial PC and CNC positioning motors

to completely automate hinge, pattern processing

and lock locations. Door files can be created with the

software which can reference barcode labels, or be

selected from an on screen list for nearly instant

machine set-up. The door files hare identical to those

used in the Kval Face, Edge and DLNC series

machines so one file can be created to be used in

multiple operations. Anti-Static air blow bar to clean

door face is also included in this package.

Option

CNC Lock Face Plate with Chis-

els

Only available in combination with option AR. Adds

CNC control of face plate routing and corner squaring

of face plates. Includes programming and three addi-

tional servo motors, ball screws, drives and four cor-

ner square chisels. Plate size is limited to a maximum

size 1-1/4” x 6”. Adjustment for zero or three degrees

routing is automatic, but chisels mechanically posi-

tioned for three degree plates only

Option

Drill Gearbox and Air Motor Adds the ability to also drill holes for lever locks with

geared drill boxes. The drills operate at the same

time as the 2-1/8 bore and do not affect cycle time.

Each drilling pattern requires a different gear box, fit-

ted with a direct coupled air motor which are priced

below. With the direct coupled design, door width

minimum is 18". Changeover from one pattern to

another takes approximately 5 minutes.

Option

Sargent 4375C Drill Gearbox

with Air motor

See Above (Option W)

Option

Best 93K (Cylindrical) Gearbox

with Air motor

See Above (Option W)

Option

Schlage “D” Serial #792 Drill

Gearbox with Air motor

See Above (Option W)

Option

Yale 80-7150-0047-010 Drill

Gearbox with Air motor

See Above (Option W)

Option

Corbin/Russwin (VT30458) Drill

Gearbox with Airmotor

See Above (Option W)

Overview of the Commander III System

1-5

KVAL Commander III Service Manual

About this Manual

This manual is part of a package delivered with the machine line.

Operation Manual

Operation Manual includes the following:

Service Manual

Service Manual includes the following

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

Operation Inter-

face

Descriptions of how to power

machine line, and operator inter-

face user screens.

3Calibration Descriptions of Calibration Rou-

tines and how to use the interfaces

Tour of Com-

mander 3

Identification and descriptions of

the Commander 3 machine assem-

blies.

Chapter Title Description

1Introduction Safety Information.

2System IT Admin-

istration

Descriptions of the PLC system,

and computer system.

3Maintenance Maintenance steps for the

machine line

4Trouble Shooting Troubleshooting tips and theory of

operation.

Overview of the Commander III System

KVAL Commander III Service Manual

1-6

KvalCAM Reference Manual

KvalCAM Reference Manual includes the following

Chapter Title Description

1KvalCAM reference Description of the Interface

2KvalCAM Examples Examples of Common Door Job

Features

3KvalCAM Common

Terms

Common terms associated with

KvalCAM

Safety First!

1-7

KVAL Commander III Service Manual

Safety First!

Safety Sheet Sign-Off Sheet

At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-

teria to understand before operating the machine. It is highly recommended that personnel operat-

ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be

signed and kept for records. See “Safety Sign-Off Sheet” on page 1-20.

Safety Terminology of Labels

In addition to the nameplate, Kval machines may have other warning labels or decals that provide

safety information to operators. Safety labels should be clearly visible to the operator and must be

replaced if missing, damaged, 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, follow the guidelines below

to help ensure the safety of equipment and personnel.

This machine is a powerful electro-mechanical motion control

system. You should test your motion system for safety under

all potential conditions. Failure to do so can result in dam-

age to equipment and/or serious injury to personnel.

Ensure that all employees who operate this machine

are aware of and adhere to all safety precautions

posted on the machine and are trained to operate this

machine in a safe manner.

Training

Safety First!

KVAL Commander III Service Manual

1-8

Never operate the machine without proper eye and

ear protection.

Protective Gear

• 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.

• 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 performing any mainte-

nance or repairs on this machine turn off the

main air disconnect. Lockout and tagout

this connection.

See “Lockout Tagout Procedure” on

page 1-12.

Compressed Air

Safety First!

1-9

KVAL Commander III Service Manual

Electrical circuitry on this

machine is protected by an

approved lockable disconnect

circuit. In addition to this equip-

ment, you must install an

approved disconnect for the

electrical power supplying this

machine.

When opening the cabinet you must first turn off the

disconnect switch. When the cabinet door is open there

is still power on the top side of the disconnect switch.

Some machines are powered by more than one supply

located 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 the elec-

trical and air pressure systems. This should be

done in accordance with applicable state and/

or federal code requirements.

Before Conducting Maintenance

Safety First!

KVAL Commander III Service Manual

1-10

Kval advises that you request an on-site state

safety review of your installation of this

machine. This is to ensure conformance to any

additional specific safety and health regula-

tions which apply in your geographic area.

Compliance with Codes and Regulations

Other Hazard Control Action

Report a Hazard

Before You Report an Accident

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 operation 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 proce-

dures to follow.

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Kval Commander 3 User manual

Brand: Kval

Model: Commander 3

Type: User manual

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Kval Commander 3 User manual

Kval Commander 3 User manual

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