Kval DL-NCB Owner's manual

Category
Power tools
Type
Owner's manual
Innovation, Quality & Honesty
DL-NCB
System Reference
Published: February 27, 2006
p/n: M-DLNCB1 rev 1.0
Proprietary Notice
This document contains confidential and trade secret information, which is proprietary to Kval, Inc. (“Kval”), and is
protected by laws pertaining to such materials. This document, the information in this document, and all rights
thereto are the sole and exclusive property of Kval, are intended for use by customers and employees of Kval, and
are not to be copied, used, or disclosed to anyone, in whole or in part, without the express written permission of
Kval. For authorization to copy this information, please call Kval Customer Support at (800) 553-5825 or fax (707)
762-0485. Outside the U.S. and Canada, call (707) 762-7367.
Copyright © 2006 Kval Incorporated. All rights reserved.
KVAL 2006 and DL-NCB are trademarks of Kval, Incorporated.
All other products are trademarks or registered trademarks of their respective holders, all rights reserved.
Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated.
Contacting KVAL
Customer Service: For further information about this manual or other Kval Incorporated products, contact
the Customer Support Department
http://www.kvalinc.com/customer_service.html (lists all the representatives, including email
addresses and phone numbers)
Mailing address:
Customer Support Department
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
Phone and Fax:
In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485
Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485
Business hours:
Technical Support: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Friday
Parts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday
(Other sales related inquiries: http://www.kvalinc.com/contact_us.html)
Email: [email protected]
Your Feedback is Welcome: To help us design products that make your job easier and your business more
successful, we’d like to gain your perspective about your user experience with our product – that is, the
manual, the machinery, the software, etc. What was easy or difficult to use or to learn? If you could change
something about the design, what would it be? Please email your comments and suggestions for improvement
to [email protected]. (NOTE: This is not a way to get customer support. For that, please refer to
the Customer Service contact information above.) Thank you!
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Table of Contents
ABOUT THIS GUIDE _______________________________________________________________________ I
Audience ............................................................................................................................................................... i
How This Guide Is Organized............................................................................................................................... i
Related Publications ............................................................................................................................................. i
Printed Documentation .......................................................................................................................... i
DL-NCB Online Documentation Library.................................................................................................ii
CHAPTER 1: INTRODUCTION _____________________________________________________________ 1-1
Overview of the DL-NCB...................................................................................................................................1-1
Operation Description................................................................................................................................1-2
Safety First! .......................................................................................................................................................1-2
Safety Guidelines ......................................................................................................................................1-2
Lock Out Procedure...................................................................................................................................1-4
Lock and Tag Out Guidelines............................................................................................................1-5
CHAPTER 2: BASIC OPERATION __________________________________________________________ 2-1
Operator’s Tour.................................................................................................................................................2-2
Machine Tour.............................................................................................................................................2-2
Orientation to Axes and Coordinates.................................................................................................2-6
KVAL 2006 User Interface.........................................................................................................................2-7
Launching the KVAL 2006 User Interface.........................................................................................2-7
KVAL 2006 User Interface Visual Tour..............................................................................................2-7
Keystroke Shortcuts...........................................................................................................................2-8
Entering Data.....................................................................................................................................2-8
Touch Screen Interface.............................................................................................................................2-8
Main Menu .........................................................................................................................................2-8
Run Screen........................................................................................................................................2-9
Manual Run Screen.........................................................................................................................2-10
Turning the DL-NCB On and Off.....................................................................................................................2-11
Powering Up the DL-NCB........................................................................................................................2-11
Powering Down the DL-NCB...................................................................................................................2-12
Emergency Shutdown and Recovery ..............................................................................................2-13
Homing the DL-NCB .......................................................................................................................................2-14
Selecting the Feed Mode................................................................................................................................2-16
Feed Off (Manual Feed) Mode................................................................................................................2-16
Auto-Feed Mode......................................................................................................................................2-17
Feed-Thru Mode......................................................................................................................................2-17
Reverse Feed Mode................................................................................................................................2-17
Cutting Doors ..................................................................................................................................................2-18
Creating and Executing a Temporary Door File......................................................................................2-19
Running Pre-Defined (Saved) Door Files................................................................................................2-21
If There Is Trouble ...................................................................................................................................2-22
Canceling a Cut.......................................................................................................................................2-22
Abort & Restart ................................................................................................................................2-22
Override Count.................................................................................................................................2-22
Restarting a Door File..............................................................................................................................2-22
CHAPTER 3: ADVANCED OPERATION______________________________________________________ 3-1
Advanced Touch Screen Functions..................................................................................................................3-2
Main Menu.................................................................................................................................................3-2
Run Screen................................................................................................................................................3-3
Manual Run Screen...................................................................................................................................3-4
Tool Changer Screen ................................................................................................................................3-5
Machine Data Screen................................................................................................................................3-6
Creating and Saving New Templates ...............................................................................................................3-6
Creating and Saving a New Rectangle Template.....................................................................................3-7
Creating and Saving a New Hole Template ...................................................................................................3-8
Creating and Saving a New Special Template..........................................................................................3-9
Creating a New Template from an Existing Template ............................................................................3-10
Modifying (Permanently) an Existing Template ..............................................................................................3-11
DL-NCB System Reference
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Deleting Templates......................................................................................................................................... 3-12
Creating and Saving a Permanent Door File.................................................................................................. 3-13
Creating a New Permanent Door File..................................................................................................... 3-13
Creating a Permanent Door File from an Existing Door File .................................................................. 3-14
Modifying (Permanently) an Existing Door File .............................................................................................. 3-15
Deleting a Door File........................................................................................................................................ 3-16
Automatic Tool Changer................................................................................................................................. 3-17
Disabling Tool Holder Locations............................................................................................................. 3-17
Changing a Tool Manually.............................................................................................................................. 3-18
Changing a Tool Bit ........................................................................................................................................ 3-19
Calibrating the DL-NCB .................................................................................................................................. 3-21
Calibrating the Tool Changer.................................................................................................................. 3-21
Determining Which Calibration Stage to Use.................................................................................. 3-21
Preparing to Calibrate the Tool Changer ........................................................................................ 3-21
Tool Calibration, Stage 1: Calibration Bolt...................................................................................... 3-23
Tool Calibration, Stage 2: Tool Offset............................................................................................. 3-27
Tool Calibration, Stage 3: Tool Holders.......................................................................................... 3-31
Calibrating Cut Accuracy......................................................................................................................... 3-33
CHAPTER 4: SYSTEM IT ADMINISTRATION __________________________________________________4-1
System Architecture.......................................................................................................................................... 4-1
Backing up System Files................................................................................................................................... 4-1
CHAPTER 5: MAINTENANCE_______________________________________________________________5-1
Maintenance Schedule ..................................................................................................................................... 5-1
Daily........................................................................................................................................................... 5-1
Weekly....................................................................................................................................................... 5-1
May and December Checkups.................................................................................................................. 5-2
Lubrication Requirements................................................................................................................................. 5-2
Linear Bearings......................................................................................................................................... 5-2
Flange Bearing and Pillow Blocks............................................................................................................. 5-2
Approved Lubrication Products for Lubricators......................................................................................... 5-2
Gear Motor Lubrication Requirements...................................................................................................... 5-3
Adjusting the Air Line Lubricator (not available on all machines)............................................................. 5-3
Priming the Air Line Lubricator.................................................................................................................. 5-3
Grease Points for Carriage ....................................................................................................................... 5-4
Maintaining the Cutter Motor Spindle ............................................................................................................... 5-6
Preparing the Machine for Spindle Maintenance...................................................................................... 5-6
Checking and Adjusting the Drawbar Extension....................................................................................... 5-7
Cleaning and Lubricating the Spindle Clamping Assembly...................................................................... 5-9
CHAPTER 6: TROUBLESHOOTING _________________________________________________________6-1
Solutions to Common Problems....................................................................................................................... 6-1
Using the Touch Screen’s Troubleshooting Utility............................................................................................ 6-2
Main Troubleshooting Menu...................................................................................................................... 6-2
Homing Troubleshooting Screens..................................................................................................... 6-3
Plunge Troubleshooting Screen........................................................................................................ 6-5
Auto-Feed Troubleshooting Screen .................................................................................................. 6-6
Servos Troubleshooting Screen........................................................................................................ 6-7
Warning Pop-up Screen.................................................................................................................... 6-8
Using the Touch Screen’s Status Displays....................................................................................................... 6-9
DL-NCB Machine I/O Status Screens....................................................................................................... 6-9
Frame Status Screen......................................................................................................................... 6-9
Carriage Status Screen................................................................................................................... 6-11
Correcting Cut Accuracy Problems................................................................................................................. 6-12
Troubleshooting the Air Cylinders................................................................................................................... 6-13
Adjusting Cylinder Extension Speed:...................................................................................................... 6-14
Adjusting Cylinder Retraction Speed:..................................................................................................... 6-14
Troubleshooting Electrical Problems.............................................................................................................. 6-15
If The Power Stops During Normal Operation ........................................................................................ 6-15
Troubleshooting with the Status Light Panel .......................................................................................... 6-16
Adjusting Limit Switches................................................................................................................................. 6-19
Troubleshooting Photo Detectors................................................................................................................... 6-20
Getting Help from Kval.................................................................................................................................... 6-21
Product Return Procedure ...................................................................................................................... 6-21
INDEX___________________________________________________________________________________XI
p/n: M-DLNCB1 rev 1.0 February 27, 2006 i
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
About This Guide
This guide describes how to operate, maintain and troubleshoot the DL-NCB, a numerically
controlled door cut-out system.
Audience
This guide is written for machine operators and factory technicians who are responsible for
operating and maintaining the DL-NCB machine.
How This Guide Is Organized
This guide is organized as follows:
Chapter 1: “Introduction
Provides a brief introduction to DL-NCB and identifies safety precautions.
Chapter 2: “Basic Operation
Provides and introduction to the operator features, and provides procedures for accomplishing
basic operator tasks.
Chapter 3: “Advanced Operation
Provides procedures for accomplishing advanced operator and system administration tasks.
Chapter 4: “System IT Administration
Provides procedures and guidelines for DL-NCB system IT administration.
Chapter 5: “Maintenance
Describes how to maintain the DL-NCB.
Chapter 6: “Troubleshooting
Provides problem descriptions and resolutions for troubleshooting the DL-NCB.
Related Publications
Printed Documentation
In addition to this System Reference, the following documents are provided with the product
(printed) and are also provided in Acrobat PDF format (see DL-NCB Online Documentation
Library below).
Document Description Location (in addition to online)
DL-NCB Unpack
and Installation
Guide
(p/n: M-DLNCB2)
Provides guidelines and
procedures for site prep,
unpacking, positioning, and
installing the DL-NCB system
Top-most item inside the “Open Me
First” box, found on the out-feed end
of the DL-NCB machine (as shipped)
System Reference binder
Customer Layout
Diagram Diagram showing the DL-NCB
and related facility
requirements, in context to your
facility and manufacturing line
System Reference binder (look for the
separate tab for this item)
System
Schematics Complete electrical schematics
for the DL-NCB system System Reference binder (look for the
separate tab for this item)
DL-NCB System Reference
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
ii
DL-NCB Online Documentation Library
Kval provides a library of all system related documentation (including documentation for system
components) in Acrobat PDF format. The library can be accessed in the following locations:
Kval folder on the DL-NCB machine’s computer desktop. Open the folder and double-click
on the “Documentation Library” shortcut.
System resource CD. This CD (labeled “DL-NCB Resource Library”) is tucked into the
pocket of the System Reference binder.
Kval website at http://www.kvalinc.com/support/documentation
p/n: M-DLNCB1 rev 1.0 February 27, 2006 1-1
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Chapter 1: Introduction
This chapter provides a description of the DL-NCB product and identifies safety guidelines that
you should follow to ensure safety to personnel and equipment.
Overview of the DL-NCB
The DL-NCB computer-controlled door light cut-out machine is designed to rout lock face holes,
viewer holes, and lights in doors made of fiberglass, steel or wood.
Notable features of this machine include touch-screen controls, automatic tool selection to match
the door material type, automatic door positioning and width adjustment, and a routing cycle that
does face boring for locks and cut-outs for door lights.
The spindle is powered by a 3-phase 11-horsepower variable-speed high-frequency motor. A
precision tool-holder chuck is mounted on the motor shaft. The on-board computer selects the
spindle speed and tooling (from a four-position tool holder) according to the type of door being
machined, whether steel, fiberglass or wood, and the type of cut being made.
The standard DL-NCB is configured for residential steel or fiberglass doors, with the capability of
machining a wide range of doors ranging from 12-inch wide sidelights to doors that are 4 feet
wide by 8 feet high.
All machine programming is done from the DL-NCB operator’s station, which features a touch
screen interface that replaces most of the manual switches on the machine. In addition,
programming can be done from a personal computer in an office or other remote location by way
of an Ethernet connection. By filling in a few data fields in KVAL’s operator interface software,
KVAL 2006, only a minute or two is needed to create a program for an entirely new cut-out
specification for regular shapes such as rectangles, circular and multiple cuts. KVAL can help
with programs to accommodate specialized cuts or machining processes for irregular curves, such
as ovals or reversing arcs.
Maximum cut-out sizes are limited to within 3 inches of a door’s top or bottom and to within
1-1/2 inches from the edges of the stiles. Once these shapes have been entered and saved, they
may be instantly called up and placed on a “run” list. If created at a remote location, these run lists
can be transferred to the machine over a standard Ethernet network.
The DL-NCB may be automated even further by equipping it with optional optical scanning
hardware that will read the operation to be done to a specific door from a barcode attached to that
particular door unit. KVAL has all the technical expertise needed to help your company’s data
processing department develop the interface needed to link your DL-NCB’s barcode reading
ability with your company’s existing order entry system.
Standard computer hardware in the DL-NCB includes a Pentium-based CPU running Windows
XP. Included are two Ethernet cards, one dedicated to communication with the internal Galil
motion controller, and the other available for networking to the rest of your facility and access to
the Internet. All DL-NCB installations require that broadband Internet access be provided by the
client so KVAL can perform real-time diagnostics and install program updates. Browser access to
http://www.kvalinc.com/support is available from the DL-NCB.
On-board diagnostic programs allow the operator to quickly and easily identify the source of any
errors and failures, even after they have occurred.
DL-NCB System Reference
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
1-2
Operation Description
Doors are typically fed from an automatic de-stacker, such as the KVAL Handler or the KVAL
ON-3. As the door approaches the DL-NCB’s in-feed zone, sensors detect its width. The in-feed
fence may take as much as five seconds to open or close as needed. As the DL-NCB draws the
door in, the feed belt shifts to a slower speed just as the door reaches a position registration stop
for clamping.
Once clamped, the router plunges into the door and goes through its programmed sequence for
cutting lock and light patterns. The routing head reciprocates during the cutting operation to
maximize tool life.
After the cutting sequence is finished, the clamps automatically release and the door passes out of
the machine through a clean-off tunnel at the out-feed end to remove chips, foam and dust.
Safety First!
The DL-NCB is a powerful electro-mechanical motion control system. You should test your
motion system for safety under all potential conditions. Failure to do so can result in damage to
equipment and/or serious injury to personnel.
Safety Guidelines
In addition to the caution and warning labels affixed to the DL-NCB system, follow the guidelines
below to help ensure the safety of equipment and personnel.
Guideline Description
Safety Training Insure that all employees who operate this machine are aware of and adhere
to all safety precautions posted on the machine and are trained to operate this
machine in a safe manner.
Protective Gear Never operate the machine without proper eye and ear protection.
Entering the Safety
Cage When changing tools:
Opening the safety cage gate will only disable the servo drives and does
not disconnect power. This gate is only intended to allow you access to
the collets in the tool holder without having to home the machine after.
Never reach past the Tool Changer or touch any other part of the
machine while power is still on. (See machine diagram on page 2-2.)
When the machine is on:
o Never reach hands beyond safety cage. Servo motors can
unexpectedly move quickly and out of control.
o Do not clear slugs out of the machine while it is running.
o Never perform any maintenance while machine is running.
o Never clean the machine while running.
o Never walk away from the machine while running.
Compressed Air The compressed air system connected to this machine should have a three-
way air valve for shut-off and pressure relief. The air supply providing the
pressure to this machine also has a three-way air valve for the supply line.
All cylinders on machine are under high pressure and can be very
dangerous when activated. Before performing any maintenance or
repairs on machine turn the main air disconnect off. Lockout and
tag out this connection.
Chapter 1: Introduction
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons. 1-3
Guideline Description
Electrical Electrical circuitry on this machine is protected by an approved lockable
disconnect circuit. In addition to this equipment, you must install an approved
disconnect for the electrical power supplying this machine.
This machine is supplied by more than one power supply and is supplied at
two different locations. Before performing any repairs or maintenance, lockout
and tag out both locations. 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. All maintenance and repairs to electrical
circuitry should only be performed by a qualified electrician.
Before Conducting
Maintenance Prior to performing any maintenance, repairs, cleaning or when clearing
jammed debris, you must disconnect, tag out, or lock out the electrical and air
pressure systems. This should be done in accordance with the state and/or
federal code requirements.
Compliance with
Codes and
Regulations
KVAL Inc. advises that you request an on-site state safety review of your
installation of this machine. This is to ensure conformance to any additional
specific safety and health regulations which apply in your geographic area.
Other Hazard
Control Action If you believe any part or operation of this machine is in violation of any health
or safety regulation, it is your responsibility to immediately protect your
employees against any such hazard and bring the matter to our attention for
review and correction, if deemed advisable.
Additional detailed safety guidelines are included in the operating instructions
of this manual. KVAL will be pleased to review with you any questions you
may have regarding the safe operation of this machine.
Still has power in
OFF position
3 phase high
voltage
110 VAC
Power
DL-NCB System Reference
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
1-4
Lock Out Procedure
This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991.
Use the following lock-out procedure to secure the DL-NCB while it is powered down. During a
lock out, you disconnect all power and shut off the air supply. Be sure to use the tag-out
guidelines noted below (page 1-5).
To lock out the DL-NCB
1. Assess the equipment to fully understand all energy sources (multiple electrical supplies, air
supply and pressure, spring tension, weight shifts, etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration of the shutdown.
3. Obtain locks, keys, and tags from your employer’s lockout center.
4. Disconnect power (two disconnection locations):
NOTE: Always lock out electrical disconnects on both the large
and small electrical cabinets:
a. Turn the disconnect switch 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 tag-out guidelines below. (see example below)
b. Turn the disconnect switch on the smaller 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 tag-out guidelines below.
When multiple people
are working on the
machine, each person
needs to have a lock
on the handle in the
extra holes provided.
Chapter 1: Introduction
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons. 1-5
T
yp
ical ta
g
s
5. Turn the main air valve to the OFF position and
place a padlock through the hole (see illustration).
NOTE: Place your tag on the padlock, as per the
tag-out guidelines below.
6. Once the locks and tags are in place, try to operate
the machine to ensure all energy sources are
defeated.
7. When maintenance or repairs are completed, the
person who performed 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 locks and tags can then be removed (only by the person[s] who placed them), and the
machine can be re-energized.
10. The tags shall be destroyed and the locks and keys returned to the lockout center.
Lock and Tag Out Guidelines
Place a tag on all padlocks. On the tags, include
your name and date.
These locks are only to be removed by the person
on the tag.
If more than one person is working on the
machine, then each additional person places a
lock and tag on each disconnect.
You may only remove your own lock and tag.
NOTE: When many
people are all working
on the same machine
you will need a multiple
lockout device, such as
the one shown here.
Follow the P-R-O-P-E-R lockout rule of thumb:
P ........ Process shutdown
R ........ Recognize energy type (electrical, pneumatic, mechanical, etc.)
O ........ OFF! Shut off all power sources and isolating devices
P ........ Place lock and tag
E ........ ENERGY: Release stored energy to a zero-energy state
R ........ Recheck controls and test to insure they are in the “OFF” state
p/n: M-DLNCB1 rev 1.0 February 27, 2006 2-1
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
Chapter 2: Basic Operation
This chapter provides the procedures for basic operation of the DL-NCB. (For descriptions and
procedures for advanced operator features, refer to Chapter 3, Advanced Operation.)
This chapter contains the following information:
Operator’s tour:
Machine tour ................................................................................................. 2-2
o Orientation to axes and coordinates .................................................... 2-6
User Interface tours:
o KVAL 2006 user interface tour .......................................................... 2-7
o Touch Screen interface tour ................................................................ 2-8
Basic operations:
Turning the machine on and off .................................................................. 2-11
Homing the DL-NCB .................................................................................. 2-14
Selecting the feed mode .............................................................................. 2-16
Cutting doors:
o Overview .......................................................................................... 2-18
o Creating and executing a temporary door file .................................. 2-19
o Running pre-defined door files ......................................................... 2-21
o Canceling a cut in progress ............................................................... 2-22
o Restarting a door file ........................................................................ 2-22
Before operating the DL-NCB, be sure to review the safety guidelines provided on page 1-2.
DL-NCB System Reference
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
2-2
Operator’s Tour
This section provides an overview of the features of the machine most frequently used by operators
(for example: status lights, operator interface, Touchscreen interface). For advanced operator
features, refer to Chapter 3, Advanced Operation.
Machine Tour
(See machine item descriptions below)
Rear Access
Gate
E-Stop Switch
(could be another next
to Tool Access Gate
)
Call Door
Foot Pedal
Manual Reverse
Feed & Width
Adjust Buttons
Out-Feed end
of machine
Drive Reset
Buttons
In-Feed end
of machine
Fixed Fence
Adjustable
Fence
Cutter Gantry
Tool Changer
Tool Changer
Access Gate
Operator’s Station
Touchscreen
Operator Panel
Computer, Monitor
Status Light Panel
Chapter 2: Basic Operation
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons. 2-3
Machine Item Descriptions:
Cutter Gantry and Tool Changer:
(view from In-Feed side of machine)
Cutter Gantry: Comprises the part of the machine that moves the Cutter Head into position to
make cuts on the door. It has an X carriage that moves up and down the length of the machine
(along the X axis) carrying the Y carriage which traverses the width of the door (Y axis) and
has the Cutter Head attached to it.
Tool Changer: The Tool Changer holds up to four Tools, each in it’s respective Tool Holder.
During normal operation, the machine automatically moves to the Tool Changer to exchange
tools, ensuring it has the tool appropriate to the type of door being cut (steel or fiberglass). For
more information about the Tool Changer, see page 3-17.
Tool: Comprises the cutter bit (either a single flute pointed cutter for
steel or a double fluted carbide cutter for wood or fiberglass) and the
Collet Assembly that holds the bit. (See illustration at left.)
Collet Assembly: Considered part of the “Tool,” it holds the bit
(secured with a special nut). The top of the Collet Assembly is the
part that allows the tool to be held securely in the Tool Holder (on
the Tool Changer arm) and in the Cutter Head.
Tool Changer
Tools
(in Tool Holders)
Tool
(in Cutter Motor)
Cutter Head
Cutter Gantry
Bit
Collet
A
ssembl
y
Tool
DL-NCB System Reference
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
2-4
E-Stop Switch: This switch is to be used when the
machine is out of control or is about to damage
personnel or equipment. See page 2-13 for details.
Rear Access Gate: Provides access to the bearing and
servo motors on the back of the machine.
Opening this gate has the same effect as
activating an E-Stop.
Tool Changer Access Gate: Provides access to the
Tool Changer, Cutter Head (for changing tools), and
other items at the in-feed side of the machine.
Opening this gate disables the drives and prevents
the machine from moving..
Drive Reset Buttons:(Located on front of High-Frequency Cabinet)
If one of these buttons is lit, it indicates that the respective motor drive (Cutter, Feed or Width-
Adjust) has a fault. For further fault analysis, a fault code is displayed on the drive, located
inside the high-frequency cabinet. To reset the drive, press the button.
Start Reverse Feed Sequence and manual Width Adjust buttons: These buttons are for use
while operating the machine in Reverse Feed Mode (see page 2-17 for details)
Call Door Foot Pedal: Use the pedal to manually advance the door in the machine (see page
2-17 for details).
E-Stop Functionality
When an E-Stop switch is
activated, cutting stops, the door is
unclamped, all motors deactivate,
and all I/O power is killed. Only
the computer and Galil motion
controller remain powered.
The machine responds in the same
way if you:
Press the STOP button on the
operator’s station.
Open the Access Gate closest
to the E-Stop Switch.
Chapter 2: Basic Operation
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons. 2-5
Operator’s Station:
Monitor (computer): Use for running KVAL 2006 software (see page 2-7), accessing
other system resources in the KVAL folder on the desktop, and accessing the network
and Internet.
Control Panel buttons/switches:
o Control Transformer button: Controls power to control circuits and computer.
Push in to kill power to machine, pull out to restore power (see pages 2-11
and 2-12 for related power up and power down procedures).
o Machine Start and Stop buttons: Controls power to the machine, with the
exception of the computer and control circuits. The Control Transformer button
must be ON (pulled out) for these buttons to function.
o Reset Drives button: Resets X-axis and Y-axis servo motor drives.
o Speed Select switch: Selects cutting speed (only affects speed when the cutter is
down).
o Disable Auto Feed button: When ON, it disables the Auto-Feed mode. Motors
are still enabled for manual control.
Touchscreen:
o Basic Operation Screens: see page 2-8.
o Advanced Operation Screens: see page 3-2.
o Troubleshooting Screens: see page 6-2.
o Machine and I/O Status Screens: see page 6-9.
Status Light Panel. All lights are illuminated on successful power-up. See page 6-16
for how to use these status lights for electrical troubleshooting.
NOTE: The work surface (under the keyboard and mouse) lifts up to provide storage for
manuals and other items.
Monitor
(shows KVAL 2006
Interface)
Control Panel
Touch Screen
Status Light Panel
DL-NCB System Reference
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
2-6
Orientation to Axes and Coordinates
Item Descriptions:
Home: The corner of the machine (out-feed end of the fixed fence) that the Cutter Head travels
to during the homing operation. All measurements are referenced from this point (home position
is X:0.000, Y:0.000). For details on homing, refer to page 2-14.
X Axis: Travel along the length of the door.
Y Axis: Travel across the width of the door.
Positioning coordinates (+ and –): Most cut parameters that you enter in the KVAL 2006
interface are relative to the following convention:
X axis:
Positive (+) direction is toward the out-feed end of the machine.
Negative (–) direction is toward the in-feed end of the machine.
Y axis:
Positive (+) direction is toward the fixed fence.
Negative (–) direction is toward the adjustable fence.
Primary Stop: The door stop on the out-feed end of the machine. This stop is usually used for
Left Hand doors. (A Left Hand door is a door that is fed into the machine top first).
Secondary Stop: The door stop on the in-feed end of the machine. This stop is usually used for
Right Hand doors. (A Right Hand door is a door that is fed into the machine bottom first).
Fixed Fence: This is the non-movable fence that the edge of the door clamps against.
Adjustable Fence: This is the movable fence (opposite the Fixed Fence) that the edge of the
door clamps against. It slides back and forth to adjust to the size of the door.
In-feed end of machine: This is the end of the machine near the Tool Changer. Typically doors
are feed into the DL-NCB at this end from a door de-stacking machine, such as the ON-3.
Out-feed end of machine: This is the end of the machine nearest the Operator’s Station.
Typically, doors are moved out this end to the next part of the door processing line. You can
feed a door into the machine from this end if the Reverse Feed mode is selected via the
Touchscreen (see page 2-17 for details).
+
+
X Axis
Secondary
Stop
Fixed
Fence
Primary
Stop
In-Feed
end
Adjustable
Fence
Y Axis
Out-Feed
end
Home
Location Right-hand
door
View of machine without Cutter Gantry
Chapter 2: Basic Operation
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons. 2-7
KVAL 2006 User Interface
You use the KVAL 2006 software program, in conjunction with the Touch Screen menus, to control
the DL-NCB.
Use the KVAL 2006 software to define and execute door files, which contain the specifications for
the cuts the DL-NCB makes on the doors. (Note: The unit of measure for all door specifications is
inches.)
Use the Touch Screen menus to manually control the DL-NCB’s mechanical operations and
movement, select operation modes, and conduct troubleshooting and maintenance functions. For
details on the Touch Screen menus, see page 2-8.
Launching the KVAL 2006 User Interface
On the Operator’s Station computer, the KVAL 2006 user interface, in addition to other system
administration software, has a shortcut on the desktop in a folder called “KVAL.” To launch the
KVAL 2006 user interface, open the KVAL folder and double-click the KVAL2006.EXE shortcut.
KVAL 2006 User Interface Visual Tour
Following is a general overview of the KVAL 2006 user interface functions. Details about the
various interface elements are provided in context to the procedures for homing the machine
(see page 2-14) and cutting doors (see pages 2-18 through 2-22).
Displays the specs for a
selected door, or for a
selected cut.
This area displays
the cuts to be
made on the door.
Click this button to
download the selected
door file. The cutting
commences after the
door is clamped into
the machine.
Displays either:
o Door files that can be
downloaded & run.
o Cut templates that can
be assigned to a door
file.
o List of templates as
assigned to a specific
door file.
These buttons are used
while defining or
modifying door files or
cut templates.
These buttons are used
to cancel a cut in
process. See page 2-22
for details.
Displays the real-time X-Y-Z
location of the cutter head.
“Width” displays the width of
the door presently clamped
into the machine (measured
by the machine).
To Home the machine, click
“Maint” once, then click the button
below it (“Home”). See page 2-14
for details.
To enter Calibration mode (see
page 3-21) click “Maint” twice.
Click this button to
finish processing
the current door, but
clear all subsequent
door files. See page
2-22 for details.
DL-NCB System Reference
p/n: M-DLNCB1 rev 1.0 February 27, 2006
This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.
2-8
Keystroke Shortcuts
Keystroke Shortcut Description
F1 Stops the downloaded door file from being executed by the DL-NCB.
F2 After pressing F1, you can then use the F2 key to clear the downloaded
door file from the DL-NCB and make it ready to receive another door
file.
F5 Creates a temporary door file. This is a quick way to enter door
parameters before cutting the door. This is an alternative to using a
saved (permanent) door file, or using a barcode.
F8 Downloads the loaded door information to the DL-NCB. The machine
will run as soon as the door clamp is engaged.
Entering Data
When entering data for a door or template, enter the data in the respective field and press the Enter
key to proceed to the next field.
All measurements are in units of inches.
TIP: When entering values, you can type in fractions and let the software calculate the decimal
equivalent. For example, if you type “35 7/8” (place a space between “35” and 7/8”) into a
parameter field and press the Enter key, the software automatically converts the value to
35.875 inches.
Touch Screen Interface
The following is an overview of the touch screen functions for basic machine operation.
For details on other touch screen functions, see:
Advanced operation screens (see page 3-2)
Troubleshooting screens (see page 6-2)
Status Display screens (see page 6-9)
Main Menu
See Run screen description
below (page 2-9)
See Manual Run screen
description below (page 2-10)
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110
  • Page 111 111
  • Page 112 112

Kval DL-NCB Owner's manual

Category
Power tools
Type
Owner's manual

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI