Kval Commander III User manual

Innovation, Quality & Honesty

Commander III Door System

With KvalCam®

Commander III Service Manual

Service Manual

Published: May 4, 2021

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 Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the

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

Manual Part Number: DOC-202_3-SRVKvalCAM

The Commander-III 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 Commander III 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 userexperience@kvalinc.com. (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 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

KVALCAM 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.

1.

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.

KVAL Commander III Service Manual

Table of Contents

Chapter 1 Introduction to the Commander III

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

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

Table of Options...................................................................................1-3

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

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

Safety First!.............................................................................. 1-6

Safety Sheet Sign-Off Sheet.................................................................1-6

Safety Terminology of Labels................................................................1-6

Safety Guidelines..................................................................................1-6

Lockout Tagout Procedure..................................................................1-10

Follow the P-R-O-P-E-R lockout rule of thumb...................................1-12

Zero-Energy to Start-Up........................................................... 1-13

Zero-Energy State to Start-Up to Operating State ..............................1-13

Getting Help from KVAL........................................................... 1-15

On-Line Help.......................................................................................1-16

Product Return Procedure ..................................................................1-16

How to Download the Service Application ............................... 1-18

Download Application .........................................................................1-18

Safety Sign-Off Sheet .............................................................. 1-21

A Note to the Operator:.......................................................................1-21

Chapter 2 System IT Administration

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

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

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

About Backing up the Data ...................................................... 2-3

About Remote Connection to KVAL Service............................ 2-4

Network Diagram ..................................................................................2-4

Chapter 3 Maintenance of the Commander III

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

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

Commander III System

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

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

Sample of Grease Locations for the Machine.......................... 3-21

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

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

KVAL Commander III Service Manual

Cutting Head Base..............................................................................3-25

Cutting Head Tools .............................................................................3-26

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

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

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

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

Replacing Bits in the Front Section ......................................... 3-31

Inspect and Clean Collet Assembly. ...................................................3-32

How to Access to Bit Assemblies .......................................................3-32

Remove and Replace the Router or Pre-Drill Bits ..............................3-33

Remove and Replace the Chisels ......................................................3-34

Replacing Tooling in the Back Section..................................... 3-35

Changing the Bore Drill.......................................................................3-35

Changing the Bolt Drill ........................................................................3-36

Changing the Face Plate Drill .............................................................3-36

Option W: Replacing Function Drill Assembly ......................... 3-37

Collet Torque Values................................................................3-38

Chapter 4 Troubleshooting the Commander III

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

About Motion Control ............................................................... 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

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

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

Commander III System

Troubleshooting with the Status Light Panel ........................... 4-19

Control Power Light OFF ....................................................................4-20

Overload Relay Light OFF ..................................................................4-21

E-Stop Light OFF ................................................................................4-21

Stop Light OFF ...................................................................................4-21

Start Light OFF ...................................................................................4-22

24VDC Light OFF ...............................................................................4-22

Network System Overview....................................................... 4-23

Connections to Servo Drives ..............................................................4-23

Connections to VFD’s (High Freq Panel)............................................4-23

Notes:

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

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 1-6

Zero-Energy to Start-

Up

Procedure to power up your machine for the first time. page 1-13

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 1-15

How to Download the

Service Application

Procedure to download an interactive application to allow

Service Technicians to control your machine and help

troubleshoot.

page 1-18

Safety Sign-Off

Sheet

A record to track operators that are trained on the

machine.

page 1-21

Overview of the Commander III System

KVAL Commander III Service Manual

1-2

Overview of the Commander III System

The Commander III incorporates CNC movements on six axes and a Beckhoff touch screen to

automate setup for up to 12 different door specifications. Custom specifications can also be

entered directly at the touch screen for special doors.

An optional package for architectural door processing is also available including a PC interface

and Kval software that allows unlimited predefined set-ups for doors up to 2-1/4” thick and bar-

code scanner for program selection.

Standard features include:

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 cor-

ner square chisels for door and jamb. Full X, Y and Z axis programming is combined with preci-

sion 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 system combined

with a servo motor drive and position lock. The traditional chain and torque limiter are retained 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 selection for lock hole backsets of 2-3/8” or 2-3/4” and

either 1” or 1-1/8” face plate width at zero or three degrees (two auto selections). 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 in-feed stop is fixed and is the zero reference

for all other settings.

Additional features include:

• Efficient hinge and lock dust take-off connections

• Auto width adjust to match incoming door

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

smooth speed transitions at door reference stops.

• 5HP lock bore, and 3 HP latch bore with precision Accuflex 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 700C door framer.

Operators Interface:

The operator interface for the Commander III is simple and requires very minimal training to cre-

ate door specifications. Dimensions are entered at the amply sized 19” Beckhoff touch screen for

hinge layout from the door top, hinge reveal, hinge size, ¼”radius, 5/8”radis or square corners,

Overview of the Commander III System

1-3

KVAL Commander III Service Manual

hinge bevel (0 or 3), lock locations, lock backset (2-3/8” or 2-3/4”) and door length. Multiple pat-

terns for screw pilot hole can be selected from a drop down list. Each specification can be

assigned to one of the twelve preset buttons, or run as a special. Left or right hand processing is

via selector switch. A key switch is provided to lock out access to specification changes.

About the Software:

The backbone of the Commander III is a Beckhoff control system with integrated components

including all Beckhoff 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 mon-

itor all machine functions from our offices in Petaluma when required.

Table of Options

Option Title Description

Option

AH

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

AR

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

FC

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

W

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

W1

Sargent 4375C Drill Gearbox

with Air motor

See Above (Option W)

Overview of the Commander III System

KVAL Commander III Service Manual

1-4

Option

W2

Best 93K (Cylindrical) Gearbox

with Air motor

See Above (Option W)

Option

W3

Schlage “D” Serial #792 Drill

Gearbox with Air motor

See Above (Option W)

Option

W4

Yale 80-7150-0047-010 Drill

Gearbox with Air motor

See Above (Option W)

Option

W5

Corbin/Russwin (VT30458) Drill

Gearbox with Airmotor

See Above (Option W)

Option Title Description

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.

Integration Package includes the following:

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 1-21.

Operation Manual includes the following:

Service Manual includes the following

Chapter Title Description

1Introduction Descriptions of Machine Line and

Safety Information.

2About KvalCAM Descriptions of the KvalCam user

interface.

3

Operation Inter-

face

Descriptions of how to power

machine line, and operator inter-

face user screens.

4Calibration Descriptions of Calibration Rou-

tines and how to use the interfaces

5Tour of the

Machine

Identification and descriptions of

the machine assemblies.

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.

Safety First!

KVAL Commander III Service Manual

1-6

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 1-21.

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.

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!

1-7

KVAL Commander III Service Manual

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 1-10.

Compressed Air

Safety First!

KVAL Commander III Service Manual

1-8

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

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!

1-9

KVAL Commander III Service Manual

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

Safety First!

KVAL Commander III Service Manual

1-10

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

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.

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