Kval Architect DI Owner's manual

Brand: Kval

Model: Architect DI

Type: Owner's manual

Innovation, Quality & Honesty

Operation and Service Manual

: 6/16/15

Architect-DI System

KVAL Architect-DI Operation/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 Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the

U.S. and Canada, call (707) 762-7367.

Manual Part Number: 070_OPSRV_ARCHDI_V1

The Architect-DI is a trademark of Kval Incorporated.

Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed

by Beckhoff Automation GmbH

Windows 7® is a registered trademark of Microsoft Corporation.

All other products are trademarks or registered trademarks of their respective holders,

or sponsorship of Kval Incorporated.

Contacting KVAL

Customer Service: For further information about this manual or other Kval Incorpo-

rated products, contact the Customer Support Department

• 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:

6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday

6:30 AM to 1:30 PM Pacific Standard Time, Friday

Parts & Service Sales:

6:30 AM to 4:00 PM Pacific Standard Time, Monday through Thursday

6:30 AM to 1:30 PM Pacific Standard Time, Friday

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

• Email: [email protected]

KVAL Architect-DI Operation/Service Manual

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

and your business more successful, we'd like to gain your perspective about your user

experience with our product - that is, the manual, the machinery, the software, etc.

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 [email protected]. (NOTE: This is not a customer support email

link. For that, please refer to the Customer Service contact information above.) Thank

you!

http://www.kvalinc.com

KVAL Architect-DI Operation/Service Manual

Chapter 1 Introduction to the Architect-DI

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

Overview of the Architect-DI System ....................................... 1-2

Available Options..................................................................................1-3

About this Manual .................................................................................1-3

Safety First!.............................................................................. 1-5

Safety Sheet Sign-Off Sheet.................................................................1-5

Safety Terminology of Labels................................................................1-5

Safety Guidelines..................................................................................1-5

Lockout Tagout Procedure....................................................................1-9

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

Zero-Energy to Start-Up........................................................... 1-12

Zero-Energy State to Start-Up to Operating State ..............................1-12

Getting Help from KVAL........................................................... 1-14

On-Line Help.......................................................................................1-14

Product Return Procedure..................................................................1-14

How to Download the Service Application ............................... 1-16

Download Application .........................................................................1-16

Safety Sign-Off Sheet .............................................................. 1-19

A Note to the Operator:.......................................................................1-19

Chapter 2 Operation of the Architect-DI

Operator’s Tour........................................................................ 2-2

In-Feed Section ....................................................................................2-3

Front Section ........................................................................................2-4

Back Section.........................................................................................2-6

Out-Feed...............................................................................................2-9

About the Electrical Panels.................................................................2-10

Description of the Six Light Panel ......................................................2-11

About Switches and Sensors..............................................................2-12

Quick Start ............................................................................... 2-14

Powering Operations for the Architect-DI ................................ 2-15

How to Power Up the Architect-DI......................................................2-15

Home the Machine..............................................................................2-16

How to Power Down the Machine.......................................................2-16

Emergency Shutdown and Recovery .................................................2-17

Table of Contents

TOC

Architect -DI

Description of User Interface Screens ..................................... 2-18

Screen Selection Menu Map.................................................... 2-19

Machine Feed Back ............................................................................2-20

Main Control Screen ...........................................................................2-20

About the Lock Plates Tab ..................................................................2-25

About the Predrill Tab ........................................................................2-26

Predrill Template References..............................................................2-27

About Manual Control Tab ..................................................................2-28

About the Status Screen.....................................................................2-30

About the Log Screen .........................................................................2-31

Important: Sequence of Calibration ......................................... 2-32

About Calibration .................................................................... 2-33

About the Calibration Buttons .............................................................2-33

How to Enter Calibration Data ............................................................2-34

Hinge Head Menu Map.......................................................................2-36

About Head Axes Calibration..............................................................2-36

About Head Chisels Calibration..........................................................2-38

About Hinge Router and Predrill Calibrations .....................................2-39

Back Section Calibration Menu Map...................................................2-40

Door Stop Menu Map..........................................................................2-44

KVAL 2012 User Interface Visual Tour .................................... 2-46

Entering Data......................................................................................2-46

Structure, how the program thinks:.....................................................2-47

Door Files: Creation and Editing.............................................. 2-48

Creating and Saving a Permanent Door File ......................................2-48

Creating a New Permanent Door File.................................................2-49

Creating a Permanent Door File from an Existing Door File...............2-50

Modifying (Permanently) an Existing Door File...................................2-51

Merging Doors ....................................................................................2-53

Creating Door Templates From Merged Doors...................................2-53

Deleting a Door File ............................................................................2-54

Chapter 3 System IT Administration

System IT Administration......................................................... 3-2

About the Architect-DI Computer..........................................................3-2

Connections on the PLC.......................................................................3-2

Backing up the Computer .....................................................................3-3

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

TOC

KVAL Architect-DI Operation/Service Manual

Chapter 4 Maintenance of the Architect-DI

Maintenance Schedule ............................................................ 4-2

Daily......................................................................................................4-2

Weekly ..................................................................................................4-2

Six Month Checkups.............................................................................4-3

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

Linear Bearings, Flange Bearing, and Pillow Blocks ............................4-4

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

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

Description of Air Input System ............................................................4-5

Adjusting the Air Line Lubricator ..........................................................4-6

Priming the Air Line Lubricator .............................................................4-6

Replacing Bits.......................................................................... 4-7

Replacing Bits in the Front Section ......................................................4-7

How to Access to Bit Assemblies .........................................................4-7

Back Section.........................................................................................4-9

Changing the Bore Drill.......................................................................4-10

Changing the Bolt Drill ........................................................................4-10

Chapter 5 Troubleshooting the Architect-DI

About Motion Control ............................................................... 5-2

Basic Control Circuit .............................................................................5-2

Typical Positioning Systems .................................................................5-4

Troubleshooting Basics ........................................................... 5-7

Before you Adjust .................................................................................5-7

Analyze the Sub Systems.....................................................................5-8

Using Sensors to Trouble Shoot .............................................. 5-10

Troubleshooting Electrical Problems ....................................... 5-11

If the Power Stops During Normal Operation......................................5-11

Troubleshooting with the Status Light Panel ......................................5-12

About VFD Troubleshooting ...............................................................5-17

Troubleshooting the Air Cylinders............................................ 5-18

Adjusting Cylinder Extension Speed:..................................................5-19

Adjusting Cylinder Retraction Speed: .................................................5-19

Network System Overview....................................................... 5-20

Connections to Servo Drives ..............................................................5-20

Connections to VFD’s (High Freq Panel)............................................5-20

TOC

Architect -DI

TOC

Chapter 1 at a Glance

1-1

KVAL Architect-DI Operation/Service Manual

CHAPTER 1 Introduction to the Architect-DI

This chapter provides an overview of the KVAL Architect-DI System and important safety infor-

mation to follow when operating the machine.

Chapter 1 at a Glance

Section Name Summary Page

Overview of the

Architect-DI System

This section provides an overview of the Architect-DI. It

includes a general description and a table of available

options

page 1-2

Safety First! IMPORTANT safety information is described in this

section

page 1-5

Zero-Energy to Start-Up Procedure to power up your machine for the first time. page 1-12

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 1-14

How to Download the

Service Application

Procedure to download an interactive application to

allow Service Technicians to control your machine and

help troubleshoot.

page 1-16

Safety Sign-Off Sheet A record to track operators that are trained on the

machine.

page 1-19

CH-1

Overview of the Architect-DI System

1-2 KVAL Architect-DI Operation/Service Manual

Overview of the Architect-DI System

KVAL's Architect-DI automatically positions, routs, and bores architectural doors for hinges and

locks in about 25-30 seconds, door-to-door. This fast cycle time also includes drilling hinge screw

holes for hinge pockets and lever lock screw holes with the optional drill cartridge system.

The "DI" after the Architect's name refers to digital integration. The Windows-based computer

system and 21 servo drives are integrated into the Architect-DI to vastly reduce set-up times and

eliminate errors. All of the adjustments listed below are now fully automatic and all of them are

accomplished simultaneously in under 10 seconds.

• Door Width

• Door Length

• Door Thickness

• Left/Right Door Swing

• 1 to 4 Hinges

• Hinge Centers

• Hinge Bevel (0 or 3 degrees)

• Hinge Pocket Backset

• Pre-Drill Location & Backset for 4-1/2” Hinges

• Lock 1 Centerline and Backset

• Lock 2 Centerline and Backset

Programming:

The Architect-DI features a touch screen panel connected to a high speed computer with a Win-

dows ® operating system. Pre-programmed door files or “recipes” are accessed by touching the

on-screen drop down list, and then touching the appropriate file name. Depending on the selected

file, a graphic image of the door changes the hand, number of hinges and locks, and a list of

parameters along the right edge of the screen updates. These parameters include all the items

listed, along with a list of less frequent manual adjustments, like hinge width, hinge depth, and

lock backset.

New files can be created, or existing parameters modified, by touching the part of the door image

the operator wants to change. For example, touch the second hinge to enter a new location. The

individual parameter on the screen also changes to red, and the operator can enter new dimensions

in decimals, fractions or even metric with a convenient number pad displayed at the bottom of the

screen. If preferred, a standard PC mouse and keyboard can be plugged in for data entry.

Because the system is PC based, there is virtually no limit to the number of different patterns that

can be stored. The computer is equipped with a network card to connect to your facility's com-

puter system for downloads, backups, and for remote support from our service center in Califor-

nia. Barcode scanning, which automatically reads barcode labels on incoming doors and

automatically selects the correct program pattern for that door, can be quoted on request.

CH-1

Overview of the Architect-DI System

1-3

KVAL Architect-DI Operation/Service Manual

System Vigilance:

A second user interface displays a use-friendly tabbed menu to monitor the real-time performance

of the Architect-DI. With a single click, the performance of servo motor assemblies, program

information, and machine position can be viewed. From this powerful interface, fine tuning to

servo motors can be achieved, manual control of machine can be performed, error logs can be

observed, and speed of the machine process can be controlled.

Available Options

The table below lists the available Options for this machine. Check the machine contract to verify

what options are applied to your machine.

Option Title Description

Option A1 Lever Lock Gearbox - Sargeant 6500

Series

Drill Attachment

Option A2 Lever Lock Gearbox - Yale 8071 Series Drill Attachment

Option A3 Lever Lock Gearbox - Schlage D-792

Series

Drill Attachment

Option A4 Lever Lock Gearbox - Corbin-Russwin

8VG-304 Series

Drill Attachment

Option A5 Lever Lock Gearbox - Best 093-K

Series

Drill Attachment

Option B CNC Horizontal Hinge Movement &

Hinge Corner Chisels

With this option you have the ability to not only square the 1/4

radius hinge pockets on the door, but to also use a 1/2" bit to cut a

5/8" radius hinge pocket. This option also allows you to select

your hinge pocket length & width.

Option SB Servo Back-section with Corner Squar-

ing

Architect-DI system combines very high quality hardware detail-

ing, with high speed productivity. Unique features include com-

puter controlled ball screw movements for all router and chisels,

complete with square lock face plates.Backsection will have the

ability to machine a face plate at both "0" and "3" degree. Opera-

tor can select widths from 1" to 1-1/4" wide and up to 2-3/4" in

length.

Option O Door Blow-Off System Air blow-off tube cleans dust and chips off the top of door

Option SE Single 440volt Electrical Drop

Option W Point to Point Pre-Drill Four (4) single spindle drill units (one for each hinge) with pro-

grammed motion to pre-drill holes in succession for hinge

screws. The screw pattern is saved and recalled by name The

cycle adds approximately 10 seconds to that of the multiple spin-

dle pre-drill. Requires Corner Squaring option.

About this Manual

This manual contains operation information and service and maintenance information.

It includes identification of machine assemblies, power-up and power-down steps, and informa-

tion about using the user interface.

CH-1

Overview of the Architect-DI System

1-4 KVAL Architect-DI Operation/Service Manual

The Troubleshooting and Maintenance sections are directed toward qualified service

technicians

TABLE 1- 1.

Title Part Number

Architect-DI Operation and Service Manual 070_OPSRV_Archdi

CH-1

Safety First!

1-5

KVAL Architect-DI Operation/Service Manual

Safety First!

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.

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 1-19.

Safety Terminology of Labels

In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-

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

must be replaced if missing, damaged, or illegible.

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.

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

CH-1

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 1-9.

Compressed Air

Safety First!

1-6 KVAL Architect-DI Operation/Service Manual

CH-1

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!

1-7

KVAL Architect-DI Operation/Service Manual

CH-1

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.

Safety First!

1-8 KVAL Architect-DI Operation/Service Manual

CH-1

Safety First!

1-9

KVAL Architect-DI Operation/Service Manual

Lockout Tagout 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 this machine 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 Lockout the This Machine

1. Assess the equipment to fully understand all energy sources (multiple electrical sup-

plies, air supply and pressure, spring tension, weight shifts, etc.).

2. Inform all affected personnel of the eminent shutdown, and the duration of the shut-

down.

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 illustration below).

When multiple people are

working on the machine, each

person needs to have a lock on

the handle in the extra holes

provided.

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.

CH-1

Safety First!

1-10 KVAL Architect-DI Operation/Service Manual

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

(see illustration below).

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

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.

7. Maintenance or repairs may now be completed. The person performing the work

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

that all guards and safety devices are installed.

8. 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.

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

the machine can be re-energized.

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

Lockout-Tagout Guidelines

• Place a tag on all padlocks. On a tag, each

operator must put their own name and date.

(These locks are only to be removed by the

person who signs the tag)

• If more than one person is working on the

machine, then each additional person places a

lock and tag on each disconnect.

• Only each operator may remove their own

lock and tag.

CH-1

Safety First!

1-11

KVAL Architect-DI Operation/Service Manual

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 lock and tag

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

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

CH-1

Zero-Energy to Start-Up

1-12 KVAL Architect-DI Operation/Service Manual

Zero-Energy to Start-Up

Zero-Energy State to Start-Up to Operating State

Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of

safety.

Start-up Guidelines

The following guidelines below should be followed to start the equipment.

Inspect

The equipment must be inspected for proper adjustment before starting equipment.

Clean Up

All materials and debris must be cleaned up. Any combustible materials or old parts

used during repairs must be cleaned up and/or properly disposed of.

Replace Guards

Replace all equipment guards. If part of equipment cannot be properly adjusted after

start-up with guard on, contact the KVAL Service team. See “Getting Help from

KVAL” on page 1-14.

Check Controls

Confirm that all switches are in the “OFF” position. Please be advised that some com-

ponents of the machine may start automatically 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 comprehensive safety procedure may involve additional

steps. You will need to ask your supervisor about these procedures. The company’s

lockout procedure should be posted at each machine. On larger or long-term mainte-

nance or installation projects, the company’s procedures must be explained to all new

operators and a copy of the company’s procedures should be posted on-site for the

duration of the work.

The Company’s procedures should also include provisions for safely handling shift

changes and changes in operators or new operators.Comprehensive lockout/tagout

CH-1

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Kval Architect DI Owner's manual

Brand: Kval

Model: Architect DI

Type: Owner's manual

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Kval Architect DI Owner's manual

Kval Architect DI Owner's manual

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