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Innovation, Quality & Honesty
Operation and Service Manual
: 12/14/18
Commander III Door System
KVAL Commander III 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: DOC_202_2_OPS
The Commander-III is a trademark of Kval Incorporated.
Copyright 2014 Kval Incorporated. All rights reserved.
Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed
by Beckhoff Automation GmbH
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all rights reserved. Reference to these products is not intended to imply affiliation with
or sponsorship of Kval Incorporated.
Contacting KVAL
Customer Service: For further information about this manual or other Kval Incorpo-
rated products, contact the 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:
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Parts & Service Sales:
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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 Operation/Service Manual
KVAL Commander III Operation/Service Manual
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KVAL Commander III Operation/Service Manual
KVAL Commander III Operation/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 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.......................................................................................1-15
Product Return Procedure ..................................................................1-15
How to Download the Service Application ............................... 1-17
Download Application .........................................................................1-17
Safety Sign-Off Sheet .............................................................. 1-20
A Note to the Operator:.......................................................................1-20
Chapter 2 Operation of the Commander III
About the Commander III Process........................................... 2-2
Operator’s Tour........................................................................ 2-3
Top View ...............................................................................................2-3
In-Feed Section ....................................................................................2-4
About the Operators Station .................................................................2-5
Front Section ........................................................................................2-6
Hinge Carriage.....................................................................................2-7
Back Section:........................................................................................2-8
Out-Feed:..............................................................................................2-9
About the Electrical Panels...................................................... 2-10
Commander III System
Assemblies in the Main Electrical Panel .............................................2-10
Assemblies in the High Frequency Panel ...........................................2-11
Description of the Six Light Panel ........................................... 2-12
Quick Start ............................................................................... 2-13
About Shelf Pins .................................................................................2-14
About Door and Jamb Loading ...........................................................2-15
Powering Operations for the Commander III ........................... 2-16
How to Power Up the Commander III .................................................2-16
Home the Commander III .................................................................. 2-17
How to Power Down the Commander III ............................................2-17
Emergency Shutdown and Recovery .................................................2-18
Description of User Interface Screens ..................................... 2-19
Screen Selection Menu Map...............................................................2-19
Machine Feed Back ............................................................................2-20
Controlling Access to User Screens ...................................................2-20
Main Screen........................................................................................2-21
About the Setup Screens......................................................... 2-26
About Hinge Routers Calibration ........................................................2-27
About the Chisels, Carriage, Lock Screen..........................................2-29
About Feed and H-Blocks Screen ......................................................2-31
About the Pre-Drill Patterns Screen....................................................2-32
About Manual Operation.......................................................... 2-33
Diagnostic Screen.................................................................... 2-36
About the H-Block Settings Screen ......................................... 2-37
Options .................................................................................... 2-38
Option ND: Narrow Door Fence..........................................................2-38
Option W: Lever Lock Drill (Function Drill)..........................................2-39
Option: Thickness Feelers ..................................................................2-40
Option BC: Ball Catch.........................................................................2-41
Option SJ: Split Jamb .........................................................................2-42
Chapter 3 Calibration of Commander III
Chapter 3 at a Glance.............................................................. 3-1
About Calibration ..................................................................... 3-2
Overview of the Setup Screens ............................................................3-2
Flow Chart of Calibration .....................................................................3-3
Before you Calibrate .............................................................................3-4
Thickness Feeler Option.......................................................... 3-5
KVAL Commander III Operation/Service Manual
About the KVAL Calibration Routine........................................ 3-6
Calibration Slot Drilling Specifications ..................................................3-7
Run the Calibration Routine..................................................... 3-8
Check Specifications of Calibration Slot ...............................................3-9
General Instructions to Adjust X, Y, and Z ............................................3-9
Step 1: Standard Router Calibration ...................................................3-13
Step 2: Counter Rotate Router Calibration .........................................3-14
Step 3: Pre-Drill Router Calibration.....................................................3-15
Step 4: Three Degree Offset Calibration.............................................3-16
Step 5: Lock Location Calibration .......................................................3-17
Step 6: Chisel Calibration ...................................................................3-18
Depth Adjustment Mapping ................................................................3-20
Fast Lock Plate Timing .......................................................................3-22
Slow Lock Plate Timing ......................................................................3-22
Special Options (Calibrations) ................................................. 3-24
Thickness Feeler Calibration ..............................................................3-24
Process to Calibrate Thickness Feelers .............................................3-24
Chapter 4 System IT Administration
System IT Administration......................................................... 4-2
About the Commander III Computer.....................................................4-2
Connections on the PLC.......................................................................4-2
Backing up the Computer .....................................................................4-3
About Remote Connection to KVAL Service.........................................4-3
Chapter 5 Maintenance of the Commander III
Maintenance Schedule ............................................................ 5-2
300 Cycle Maintenance Steps ................................................. 5-4
Clean, Clean, Clean!.............................................................................5-4
600 Cycle Maintenance Steps ................................................. 5-5
Check Air Gauges and Inspect Water Traps ........................................5-5
Inspect Tooling......................................................................................5-5
Empty Dust Collection Units .................................................................5-6
3,000 Cycle Maintenance Steps .............................................. 5-7
Inspect Feed Belts (If Applicable).........................................................5-7
Inspect all Photo Eyes ..........................................................................5-7
Inspect Limit Switches ..........................................................................5-7
Inspect Airlines .....................................................................................5-8
Refill Lubricators (If Applicable) ............................................................5-8
Commander III System
Grease Ball Screw Bearings.................................................................5-9
Clean Bearing Shafts............................................................................5-9
12,000 Cycle Maintenance Steps ............................................ 5-10
Inspect Chains for Proper Tension......................................................5-10
Inspect Air Cylinders...........................................................................5-10
Inspect Hydraulic Lines.......................................................................5-10
Inspect Ball Rail Shafts and Ball Screws ............................................5-11
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........5-11
72,000 Cycle Maintenance Steps ............................................ 5-12
Inspect Nuts and Bolts........................................................................5-12
Check Door Feeding Transition ..........................................................5-12
Electrical .............................................................................................5-12
Computer Backup ...............................................................................5-13
Wash Filter and Lubricator Bowls .......................................................5-13
Maintenance NO-GOES .......................................................... 5-14
Lubrication Schedule ............................................................... 5-15
Typical Lucubration Kit........................................................................5-15
Lubrication Requirements........................................................ 5-16
Pillow Block Bearing Housings ...........................................................5-16
Flange Bearing Housings ...................................................................5-17
Ball Rail Bearing .................................................................................5-17
About Taper Bearings .........................................................................5-18
Tapered Bearing Housings .................................................................5-18
Ball Screw Nut ....................................................................................5-19
Ball Screw Drive Assembly.................................................................5-19
Pulley and Idler Shafts........................................................................5-20
Sample of Grease Locations for the Machine.......................... 5-21
Front Section Servo Assemblies.........................................................5-24
Grease Locations Cutter Head ................................................ 5-25
Cutting Head Base..............................................................................5-25
Cutting Head Tools .............................................................................5-26
Back Section Grease Points ...............................................................5-27
Opt BC: Ball Catch Hub Location .......................................................5-28
Grease Location on the Frame (Feed System) ..................................5-29
Air Input with Lubrication ...................................................................5-30
Air Line Without Lubricator .................................................................5-31
Replacing Bits in the Front Section ......................................... 5-32
Inspect and Clean Collet Assembly. ...................................................5-33
How to Access to Bit Assemblies .......................................................5-33
Remove and Replace the Router or Pre-Drill Bits ..............................5-34
KVAL Commander III Operation/Service Manual
Remove and Replace the Chisels ......................................................5-35
Replacing Tooling in the Back Section..................................... 5-36
Changing the Bore Drill.......................................................................5-36
Changing the Bolt Drill ........................................................................5-37
Changing the Face Plate Drill .............................................................5-37
Option W: Replacing Function Drill Assembly ......................... 5-38
Collet Torque Values................................................................5-39
Chapter 6 Troubleshooting the Commander III
About Motion Control ............................................................... 6-2
Basic Control Circuit .............................................................................6-3
About a Typical Contactor Control ........................................... 6-4
About Contactor Troubleshooting .........................................................6-5
About Typical VFD Motor Drive Control................................... 6-6
About the VFD ......................................................................................6-7
About VFD Troubleshooting .................................................................6-8
About a Typical Pneumatic Circuit ........................................... 6-9
Typical Pneumatic Assembly ..............................................................6-10
About the Coil (Solenoid)....................................................................6-10
About Cylinder Operation ...................................................................6-11
How the Pneumatic System Works ....................................................6-11
Important Notice about Adjusting Cylinder Speed ..............................6-14
Adjusting Cylinder Extend Speed .......................................................6-14
Adjusting Cylinder Retraction Speed .................................................6-14
About Switches and Sensors................................................... 6-15
Using Sensors to Trouble Shoot.........................................................6-16
Troubleshooting Electrical Problems ....................................... 6-17
If the Power Stops During Normal Operation......................................6-17
Troubleshooting with the Status Light Panel ........................... 6-19
Control Power Light OFF ....................................................................6-20
Overload Relay Light OFF ..................................................................6-21
E-Stop Light OFF................................................................................6-21
Stop Light OFF ...................................................................................6-21
Start Light OFF ...................................................................................6-22
24VDC Light OFF ...............................................................................6-22
Network System Overview....................................................... 6-23
Connections to Servo Drives ..............................................................6-23
Connections to VFD’s (High Freq Panel)............................................6-23
1-1
CHAPTER 1 Introduction to the Commander III
This chapter provides an overview of the KVAL Commander III System and important safety
information to follow when operating the machine.
Chapter 1 at a Glance
The following information is available in this chapter
TABLE 1-1. Summary of Chapter
Section Name Summary Page
Overview of the
Commander III
System
This section provides an overview of the Com-
mander III. 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 1-6
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 1-17
Safety Sign-Off
Sheet
A record to track operators that are trained on the
machine.
page 1-20
Overview of the Commander III System
1-2
Commander III Operation and Service Manual
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
Commander III Operation and 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 nor-
mal 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 architectural 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 Chisels Only available in combination with option
AR. Adds CNC control of face plate rout-
ing and corner squaring of face plates.
Includes programming and three addi-
tional servo motors, ball screws, drives
and four corner 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 mechani-
cally positioned for three degree plates
only
Overview of the Commander III System
1-4
Commander III Operation and Service Manual
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, fitted 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)
Option W2 Best 93K (Cylindrical) Gearbox with
Air motor
See Above (Option W)
Option W3 Schlage “D” Serial #792 Drill Gear-
box 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
About this Manual
1-5
Commander III Operation and Service Manual
About this Manual
This manual is part of a package delivered with the machine line.
Operation Manual includes the following:
Chapter Title Description
Chapter 1 Introduction Descriptions of Machine Line and
Safety Information.
Chapter 2 Operation
Interface
Descriptions of how to power
machine line, and operator inter-
face user screens.
Chapter 3 Calibration Descriptions of Calibration Rou-
tines and how to use the interfaces
Chapter 4 System IT
Administration
Descriptions of the PLC system,
and computer system.
Chapter 5 Maintenance Maintenance steps for the machine
line
Chapter 6 Trouble Shoot-
ing
Troubleshooting tips and theory of
operation.
Safety First!
1-6
Commander III Operation and Service Manual
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-20.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that 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
Commander III Operation and 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!
1-8
Commander III Operation and Service Manual
Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, you must install an
approved disconnect for the
electrical power supplying this
machine.
When opening the cabinet you must first turn off the
disconnect switch. When the cabinet door is open there
is still power on the top side of the disconnect switch.
Some machines are powered by more than one supply
located at different locations. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
Prior to performing any maintenance, repairs,
cleaning or when clearing jammed debris, you
must disconnect, tag out, or lock out the elec-
trical and air pressure systems. This should be
done in accordance with applicable state and/
or federal code requirements.
Before Conducting Maintenance
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
Commander III Operation and 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!
1-10
Commander III Operation and 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
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.
/
