Kval face Owner's manual

Innovation, Quality & Honesty

Standard

Auto Feed

System Reference

Published: 7/28/08

Face

Face System Reference

Proprietary Notice

This document contains confidential and trade secret information, which is proprietary to Kval, Inc.

(“Kval”), and is protected by laws pertaining to such materials. This document, the information in this

document, and all rights thereto are the sole and exclusive property of Kval, are intended for use by cus-

tomers and employees of Kval, and are not to be copied, used, or disclosed to anyone, in whole or in

part, without the express written permission of Kval. For authorization to copy this information, please

call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call

(707) 762-7367.

KVAL 2006 and DL-NCB are trademarks of Kval, Incorporated.

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 Incorporated products,

contact the Customer Support Department

• http://www.kvalinc.com/customer_service.html (lists all the representatives, including email

addresses and phone numbers)

• Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

• 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

• Business hours:

Technical Support: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Friday

Parts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday

(Other sales related inquiries: http://www.kvalinc.com)

• Email: [email protected]

Your Feedback is Welcome: To help us design products that make your job easier and your business

more successful, we'd like to gain your perspective about your user experience with our product - that

is, the manual, the machinery, the software, etc. 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 sugges-

tions for improvement to [email protected]. (NOTE: This is not a way to get customer sup-

port. For that, please refer to the Customer Service contact information above.) Thank you!

Face a

Table of Contents

CHAPTER 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Overview of the Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Physical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety First! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Lock Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

To lock out the Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Lockout and Tagout Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Follow the P-R-O-P-E-R lockout rule of thumb. . . . . . . . . . . . . . . . . . . . . . . . . 1-6

CHAPTER 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

How to position the door for cutting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Left Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Right Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Tour: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Control Panel One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Control Panel Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Foot Switches: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Cutting Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Auto Feed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

KVAL 2006 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Launching the KVAL 2006 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

KVAL 2006 User Interface Visual Tour . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Keystroke Shortcuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Entering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Manual Run Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Powering Up the Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Powering up the system includes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Powering Down the Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Powering down the system includes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

To Power Down the Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Emergency Shutdown and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

To Resume Normal Operation after an E-Stop . . . . . . . . . . . . . . . . . . . . . 2-16

Homing the Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

To Home the Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

bFace

CHAPTER 3 Advanced Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Structure, how the program thinks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Running Pre-Defined (Saved) Door Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

To Cut a Door Using a Saved Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Door Files: Creation and Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Creating and Saving a Permanent Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Creating a New Permanent Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Creating a Permanent Door File from an Existing Door File . . . . . . . . . . . . . . . 3-7

Modifying (Permanently) an Existing Door File . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

To Make a Permanent Modification to an Existing Door File . . . . . . . . . . . 3-8

Deleting a Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

To Delete a Door File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Template: Creation and Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Overview: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Template Creation quickstart: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

The User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

The Template List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

The Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

The Parameter Value Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

The View Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Cut Types: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

To Create a New Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

To Create New Template Based on Existing Template . . . . . . . . . . . . . . . . . . . 3-17

Deleting Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

To Delete a Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

To Edit a Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Loading a Template for Editing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

How to Modify Template Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Template Parameter Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Stop Codes explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Template Shapes: Adding and Deleting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

To Add Shapes to a Template: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

To Delete Shapes from a Template: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

How to Modify Shape Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Shape Parameter Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Hole Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Rectangle Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Special Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

More on Plate Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

For multiple plate corner radii: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

CHAPTER 4 System IT Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Backing up System Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Face c

Network Integrated Door System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Door files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

File Propagation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

New Door File and Door Template file distribution . . . . . . . . . . . . . . . . . . 4-4

Network ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

DoorNum.dbf file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Barcode Reading and Parsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Parsing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

L,Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Len: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

M,Start,Stop: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

R,Length: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

How it all works together: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Remote Programming Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

CHAPTER 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

May and December Checkups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Linear Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Flange Bearing and Pillow Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Approved Lubrication Products for Lubricators . . . . . . . . . . . . . . . . . . . . . 5-4

Gear Motor Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Ball Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Adjusting the Air Line Lubricator (not available on all machines) . . . . . . . 5-5

Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Auto Feed System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Router Collets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Tool Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Collet Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

CHAPTER 6 Calibrating the FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

How to modify a Parameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Tool size and Cutting Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Top Main Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Top Router Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Bottom Main Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

dFace

Bottom Main Router Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

D1 Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

D1 Top Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

D1 Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

D1 Bottom Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

D2 Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

D2 Top Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

D2 Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

D2 Bottom Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Automated Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

D2 Neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

D2 Pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Cut Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Top Main Router X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Top Router Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

D1 X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

D1 Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

D2 X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

D2 Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Left Hand X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Right Hand X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

SSX1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

SSX2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

SSX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

SSX4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

SSX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Left Stop Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Left Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Left Stop 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Left Stop 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Left Stop 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Left Stop 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Left Stop 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Left Stop 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Left Stop 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Left Stop 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Left Stop 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Left Stop 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Right Stop Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Right Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Right Stop 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Right Stop 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Right Stop 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Right Stop 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Right Stop 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Right Stop 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Face e

Right Stop 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Right Stop 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Right Stop 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Right Stop 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

CHAPTER 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Troubleshooting the Air Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Adjusting Cylinder Extension Speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Adjusting Cylinder Retraction Speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Troubleshooting Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

If the Power Stops During Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Troubleshooting with the Status Light Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Adjusting Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Troubleshooting Photo Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Limit Switch Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

General process description: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

KVAL2006 Limit Switch Timing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Reference Bolt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Axis Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Cushion Stop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Part Location and Touch Screen assisted Troubleshooting . . . . . . . . . . . . . . . . . . . 7-21

Feed and Width Adjust I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Width Adjust and Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Center Fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Feed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Drill Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Tool Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Servo and Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Datalink Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

PLC Locations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

PLC I/O (Input - Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Galil I/O list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

PLC I/O Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

OPENNET (MAIN) PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

Port Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

MICROSMART R-1 PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Port Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

MICROSMART R-2 PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

fFace

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

Port Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

CHAPTER 8 Motion Control Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Basic Motion Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Trouble shooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Analyzing the subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Typical Positioning System electrical circuits: . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Contactor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Motor Drive Control: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

How to measure three phase Voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Typical Positioning System pneumatic circuit: . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

KVAL Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Point to Point positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Pneumatic Positing - Plunge Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Motor Positioning - Door Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Motor Positioning - Width Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Incremental control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

CNC Positioning - An Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Homing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

CNC Positioning: 1 Axis - Width Adjust . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

CNC Positioning: 2 Axis - Door Light Router . . . . . . . . . . . . . . . . . . . . . . 8-21

Getting Help from Kval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Product Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Face 1-1

CHAPTER 1 Introduction

This chapter provides a description of the Face product and identifies safety guidelines to ensure per-

sonnel safety and proper equipment use.

Overview of the Face

The KVAL Face is a computer-controlled router and drill machine designed to cut mortise lock function

holes, viewers and routed pockets necessary for exit devices and card locks. The machine features two

high frequency routers, and one drill motor for each door face, six tools total. This arrangement, with

tools on both faces, eliminates tear-out.

The tool carriages are supported on 1-1/2” linear bearing shafts for x and y travel. Rail bearing ways are

used for Z-axis movements. All three axes are powered by Baldor AC servos with Thomson ball

screws. Computer control is provided by a Galil motion controller housed in a PC computer, which pro-

vides the operator interface and program storage.

A standard windows based PC is used for programming and data storage. Machine programming can be

done locally at the Face machine, or in networked system, at a remote PC. The Face program, devel-

oped by KVAL, allows the user to easily add holes or rectangles to a door template file. A display win-

dow shows the relative location of the template and it’s components on a door.

Training and Service: The purchase and installation of The Face includes on-going phone support by

KVAL technicians from our California Service Center. A phone line connection to the machine’s

modem is required. We strongly encourage you to send your operators and maintenance personnel to

our plant to train on your new Face before it is shipped. After the machine is shipped and set in place, a

KVAL technician will visit your plant to check the machine out, make any final adjustments, and offer a

review of training.

Specifications

Typical cycle times:

• Lever locks, 2-1/8” hole and a pair of screw holes: 25 seconds

• Mortise locks: 35 to 40 seconds

• Card locks: 75 seconds

• Capacity: Accommodates doors from 1 3/8” to 2-1/4” thick, 11" to 4'0" wide,

• 5'5" to 10'0" long. The machine is capable of processing both flush and panel doors, not raised mold-

ing however. To process the face of a raised molding door requires a KVAL DL-NCB.

Physical characteristics

• Footprint Size: 119-1/2” x 106-3/4”

• Crated Dimensions: 16'L x 8'W x 6'H

• Shipping Weight: 6,000 lbs.

• {UL} Electrical panel is built according to Underwriter's Laboratories specifications and the UL

label is applied.

Introduction

1-2 Face

Face 1-3

Safety First!

The Face 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 damage to equipment and/or seri-

ous injury to personnel.

Safety Guidelines

In addition to the caution and warning labels affixed to the Face system, follow the guidelines below to

help ensure the safety of equipment and personnel.

Guideline Description

Safety Training 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.

Protective Gear Never operate the machine without proper eye and ear protection.

Entering the Safety

Cage When the machine is on:

• Never reach hands beyond safety cage. Servo motors can unexpectedly

move quickly and out of control.

• Do not clear slugs out of the machine while it is running.

• Never perform any maintenance while machine is running.

• Never clean the machine while running.

• Never walk away from the machine while running.

Compressed Air .

Electrical 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 supplying this machine.

When opening the cabinet you must first turn off the dis-

connect switch. When the cabinet door is open there is

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

maintenance and repairs to electrical circuitry should

only be performed by a qualified electrician.

Before Conduct-

ing Maintenance Prior to performing any maintenance, repairs, cleaning or when clearing

jammed debris, you must disconnect, tag out, or lock out the electrical and air

pressure systems. This should be done in accordance with the state and/or fed-

eral code requirements.

Compliance with

Codes and Regula-

tions

KVAL Inc. 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 regulations which apply in your geographic area.

The compressed air system connected to this machine should have a three-

way air valve for shut-off and pressure relief. The air supply providing the

pressure to this machine also has a three-way air valve for the

supply line. All cylinders on machine are under high pressure

and can be very dangerous when activated. Before performing

any maintenance or repairs on machine turn the main air discon-

nect off. Lock out and tag out this connection.

Still has power

in OFF position

1-4 Face

Other Hazard Con-

trol Action If you believe any part or operation of this machine is in violation of any

health or safety regulation, it is your responsibility to immediately protect

your employees against any such hazard and bring the matter to our attention

for review and correction, if deemed advisable.

Additional detailed safety guidelines are included in the operating instruc-

tions of this manual. KVAL will be pleased to review with you any questions

you may have regarding the safe operation of this machine.

Face 1-5

Lock Out Procedure

This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991.

Use the following lockout procedure to secure the Face while it is powered down. During a lockout,

you disconnect all power and shut off the air supply. Be sure to use the tagout guidelines noted below.

To lock out the Face

1.Assess the equipment to fully understand all energy sources (multiple electrical supplies, air 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.Disconnect power

a.Turn the disconnect switches on the main electrical panel to the OFF position. Then pull out

the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tagout

guidelines below. (see example below)

b.Turn the disconnect switch on the larger high-frequency panel to the OFF position. Then pull

out the red tab and place a padlock through the hole. Place your tag on the padlock, as per the

tagout guidelines below

5.Turn the main air valve to the OFF position and place a padlock through the hole (see illustration.).

NOTE: Place your tag on the padlock, as per the tagout guidelines below.

When multiple people are

working on the machine, each

person needs to have a lock on

the handle in the extra holes

provided.

1-6 Face

6.Once the locks and tags are in place and all personnel are clear, attempt to operate the machine to

ensure equipment will not operate. When maintenance or repairs are completed, the person who per-

formed the work must ensure all tools, spare parts, test equipment, etc., are completely removed and

that all guards and safety devices are installed.

7.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.

8.The lock and tag can now be removed (only by the person(s) who placed them), and the machine can

be re-energized.

9.The tags must be destroyed and the locks and keys returned to the lockout center.

Lockout and Tagout Guidelines

• Place a tag on all padlocks. On the tags, include your

name and date.

• These locks are only to be removed by the person on

the tag.

• If more than one person is working on the machine,

then each additional person places a lock and tag on

each disconnect. You may only remove your own lock

and tag.

• You may only remove your own lock and tag

Note: 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 lock and tag

E...... ENERGY: Release stored energy to a zero-energy state

R ...... Recheck controls and test to insure they are in the “OFF” state

Face 2-1

CHAPTER 2 Operation

The following chapters explain normal operation of the Face.

Operation

2-2 Face

Quick Start

Face 2-3

Quick Start

1.Apply power to the machine. See “Powering Up the Face” on page 2-13.

2.Start the KVAL2006 program. See “Launching the KVAL 2006 User Interface” on page 2-8.

3.Home the machine. See “Homing the Face” on page 4-3.

Note: If the machine has the auto feed option, it is now ready to process doors. See “Network Integrated

Door System” on page 4-3 for more information.

4. Load door file. See “Running Pre-Defined (Saved) Door Files” on page 3-3

5.Press the Door Stop foot pedel.Position the door. See “How to position the door for cutting:” on

page 2-4.

6.Press DOOR CLAMP pedal or START SEQUENCE button

7.If START SEQUENCE button was pressed, the clamps will clamp and the cutting will start; if the

DOOR CLAMP pedal was pushed, press the START SEQUENCE button.

8.If the Auto Unclamp is ON, the clamp will un-clamp after the cuts have been completed. If Auto

Unclamp is OFF, press the DOOR CLAMP foot pedal to unclamp the door.

9.If there are no more cuts, remove the door.

10.If the loaded template requires multiple positions, reposition the door on the newly extended stop and

go back to step 6.

11.Go to step 4.

2-4 Face

How to position the door for cutting:

Left Hand

1.Push door agents back stop. 2.Keeping pressure against the back-

fence, push door against the extended

left hand stop.

Right Hand

1.Push door agents back stop. 2.Keeping pressure against the back-

fence, push door against the extended

right hand stop.

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Kval face Owner's manual

Kval face Owner's manual

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