Kval DL-NCB 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.

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

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

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 is loading ...

Kval DL-NCB Owner's manual

Kval DL-NCB Owner's manual

Related papers