Kval face Owner's manual

Innovation, Quality & Honesty

Operating Instructions

Published: 9/24/08

Alliance Series

Introduction

Alliance Series a-a

Introduction

This chapter provides a description of the Alliance Series product and identifies safety guidelines to

ensure personnel safety and proper equipment use.

Overview of the Alliance Series

The Alliance System functions as a single door machine with

multiple stations controlled from a central console. Integrated

KVAL software tracks each door as it progresses, automatically

setting up the next station just as the door arrives. This allows

the Alliance to machine five different doors for five different specifications simultaneously; no setup

time is required between doors. Average productivity is one minute door-to-door for hinges and cylin-

drical or mortise locks:

• Squared hinges with screw holes.

• Cylinder locks with screw holes.

• Mortise locks with function holes.

• Card locks.

• Auto routing and squaring for vision panels.

• Viewer holes.

• T-Strikes.

• Flush bolts including deep drills to 12”.

• End detailing for closers, holders

a-b Alliance Series

Alliance Series

Table of Contents

CHAPTER 1 ........................................................................The Alliance Line 1-1

Tour of the Line ............................................................................................... 1-3

Quick Start ....................................................................................................... 1-4

How to load a door stack: .......................................................................... 1-6

Typical Alliance Product flows .................................................................. 1-7

Single Stack Feed ................................................................................... 1-7

Dual Stack Feed ......................................................................................1-7

Single Door Feed .................................................................................... 1-8

External processing ................................................................................. 1-8

Removing Single Doors from the process flow ...................................... 1-9

Stack Manipulation ................................................................................. 1-9

Mid-Cycle Shutdown and Recovery .............................................................. 1-11

Causes of Mid-cycle shutdown ................................................................ 1-11

Recovery from Mid-cycle shutdown ....................................................... 1-11

How to re-power a shutdown down machine: ...................................... 1-12

How to Manually remove uncompleted doors from the line: ............... 1-14

Manual Feed and Width control using the KVAL2006 Program .......... 1-18

CHAPTER 2 ...................................................The KVAL 2006 User Interface 2-1

Launching the KVAL 2006 User Interface ............................................. 2-1

KVAL 2006 User Interface Visual Tour ................................................ 2-1

Keystroke Shortcuts ................................................................................... 2-2

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

CHAPTER 3 ......................................................................................ON-2010 3-1

Door Stack Access ...........................................................................................3-3

To Enable the Door Stack Access Mode: ............................................... 3-3

To Disable the Door Stack Access Mode. ..............................................3-4

ON-2010 - Operator’s Tour .............................................................................. 3-5

Operators Station: ............................................................................................3-5

Control Panel ............................................................................................. 3-5

Touch Screen .................................................................................................... 3-6

OK to Home ............................................................................................... 3-6

Navigation & Control ............................................................................. 3-6

Main Menu REMOTE ............................................................................... 3-7

Feed Mode .............................................................................................. 3-7

Manual Feed: .......................................................................................... 3-7

Door Data ................................................................................................ 3-8

Alliance Series

Stack Control: .......................................................................................3-10

Navigation ............................................................................................. 3-10

Main Menu LOCAL ................................................................................ 3-11

Running Data: ....................................................................................... 3-11

Door Width Entry: ................................................................................ 3-12

How to change a door width preset: .....................................................3-13

Entering Fractional Values: ................................................................... 3-14

Lift: Move and Mode Control ............................................................... 3-14

Stack Control: .......................................................................................3-14

Feed Mode ............................................................................................ 3-16

Navigation ............................................................................................. 3-16

Ready Enter Data .................................................................................. 3-16

How to Run a Door in Manual Local Mode: ........................................... 3-17

Manual Mode ........................................................................................... 3-18

Reset Sequence: .................................................................................... 3-18

Forklift Control: .................................................................................... 3-18

Carriage Control: .................................................................................. 3-18

Stack Control: ....................................................................................... 3-19

Feed Mode: ........................................................................................... 3-19

Maintenance -1 ........................................................................................ 3-20

Data: ...................................................................................................... 3-20

Change Position: ................................................................................... 3-20

Feed Mode ............................................................................................ 3-20

Manual Feed: ........................................................................................ 3-20

Navigation: ............................................................................................ 3-20

Maintenance -2 ........................................................................................ 3-21

Touch Screen view adjustments: .......................................................... 3-21

Navigation: ............................................................................................ 3-21

Machine Data ........................................................................................... 3-22

Technical Support .................................................................................... 3-22

Homing the ON-2010 .................................................................................... 3-23

To Home the ON-2010 ......................................................................... 3-23

CHAPTER 4 ............................................................Calibrating the ON-2010 4-1

CHAPTER 5 ...........................................................................................FACE 5-1

FACE - Operator’s Tour: .................................................................................. 5-3

Control Panel .......................................................................................... 5-3

Cutting Head ........................................................................................... 5-4

Touch Screen .............................................................................................. 5-5

Main Screen ............................................................................................ 5-5

Manual Run Screen ................................................................................. 5-6

Homing the Face .............................................................................................. 5-7

Alliance Series

To Home the Face ................................................................................... 5-7

Router Collets .................................................................................................. 5-9

Tool Insertion ..........................................................................................5-9

Collet Maintenance ................................................................................. 5-9

CHAPTER 6 ................................................................. Calibrating the FACE 6-1

How to modify a Parameter: ............................................................................ 6-2

Parameters ........................................................................................................ 6-4

Tool size and Cutting Depth ...................................................................... 6-4

Top Main Router ..................................................................................... 6-4

Top Router Depth .................................................................................... 6-4

Bottom Main Router ............................................................................... 6-4

Bottom Main Router Depth .................................................................... 6-4

D1 Top .................................................................................................... 6-4

D1 Top Depth .......................................................................................... 6-4

D1 Bottom ............................................................................................... 6-5

D1 Bottom Depth .................................................................................... 6-5

D2 Top .................................................................................................... 6-5

D2 Top Depth .......................................................................................... 6-5

D2 Bottom ............................................................................................... 6-5

D2 Bottom Depth .................................................................................... 6-5

Automated Tool Selection ..........................................................................6-6

D2 Neg .................................................................................................... 6-6

D2 Pos ..................................................................................................... 6-6

Cut Location .............................................................................................. 6-7

Top Main Router X ................................................................................. 6-7

Top Router Y ........................................................................................... 6-7

D1 X ........................................................................................................ 6-8

D1 Y ........................................................................................................ 6-8

D2 X ........................................................................................................ 6-9

D2 Y ........................................................................................................ 6-9

Left Hand X .......................................................................................... 6-10

Right Hand X ........................................................................................ 6-10

SSX1: .................................................................................................... 6-11

SSX2: .................................................................................................... 6-11

SSX3 ..................................................................................................... 6-11

SSX4 ..................................................................................................... 6-11

SSX5 ..................................................................................................... 6-11

Left Stop Calibrations .............................................................................. 6-12

Left Stop 1 ............................................................................................. 6-12

Left Stop 2 ............................................................................................. 6-12

Left Stop 3 ............................................................................................. 6-13

Left Stop 4 ............................................................................................. 6-13

Left Stop 5 ............................................................................................ 6-14

Alliance Series

Left Stop 6 ............................................................................................ 6-14

Left Stop 7 ............................................................................................ 6-15

Left Stop 8 ............................................................................................ 6-15

Left Stop 9 ............................................................................................ 6-16

Left Stop 10 .......................................................................................... 6-16

Left Stop 11 .......................................................................................... 6-17

Right Stop Calibrations ............................................................................ 6-18

Right Stop 1 .......................................................................................... 6-18

Right Stop 2 .......................................................................................... 6-18

Right Stop 3 .......................................................................................... 6-19

Right Stop 4 .......................................................................................... 6-19

Right Stop 5 .......................................................................................... 6-20

Right Stop 6 .......................................................................................... 6-20

Right Stop 7 .......................................................................................... 6-21

Right Stop 8 .......................................................................................... 6-21

Right Stop 9 .......................................................................................... 6-22

Right Stop 10 ........................................................................................ 6-22

Right Stop 11 ........................................................................................ 6-23

CHAPTER 7 ......................................................................... Architect DI-DM 7-1

Architect DI-DM - Operator’s Tour 7................................................................. -3

Control Panel: ......................................................................................... 7-3

Touch Screen .................................................................................................... 7-4

Main Screen ............................................................................................... 7-4

Feed Select .............................................................................................. 7-4

Back Section Speed ................................................................................ 7-4

Hinge Speed ............................................................................................ 7-4

Navigation ............................................................................................... 7-4

Manual Run Screen .................................................................................... 7-5

Manual Feed ........................................................................................... 7-5

Navigation ............................................................................................... 7-5

Machine Data Screen ................................................................................. 7-6

Homing the Architect DI DM .......................................................................... 7-7

To Home the Architect DI DM ............................................................... 7-7

Router Collets .................................................................................................. 7-9

Tool Insertion ..........................................................................................7-9

Collet Maintenance ................................................................................. 7-9

CHAPTER 8 ................................................Calibrating the Architect DI-DM 8-1

How to modify a Parameter: ............................................................................ 8-2

Parameters ........................................................................................................ 8-4

Front Section .............................................................................................. 8-4

Alliance Series

Pocket Definitions ................................................................................... 8-4

Hinge Locations ...................................................................................... 8-4

Full Front section Calibration Procedure ................................................... 8-4

Pocket Parameters - Predrills .................................................................. 8-5

Pocket Parameters - General ................................................................... 8-5

Router Diameter ..................................................................................... 8-6

General Front Section: ............................................................................... 8-6

HINGE Z Each Pass ............................................................................... 8-6

Hinge Outfeed Stop ................................................................................. 8-6

Hinge Infeed Stop: .................................................................................. 8-6

Back Section .................................................................................................... 8-7

Router ......................................................................................................... 8-7

Router Horizontal, Vertical ..................................................................... 8-7

Router Diameter ...................................................................................... 8-7

Router Depth ........................................................................................... 8-8

3 Deg Depth ............................................................................................ 8-8

Z Each Pass: ............................................................................................ 8-8

Chisels ........................................................................................................ 8-8

Z Offset to Chisel aa ............................................................................... 8-8

Deep Mortis ............................................................................................ 8-9

DM Diameter .......................................................................................... 8-9

Z Ech DM Pass: ...................................................................................... 8-9

DM Depth: .............................................................................................. 8-9

Counter Rotating Router .......................................................................... 8-10

Cnt Rout Diam (Counter Router Diameter) .......................................... 8-10

Cnt Rout Depth: .................................................................................... 8-10

Side Drills ................................................................................................ 8-11

Side Drill Z: .......................................................................................... 8-11

Side Drill Diam: .................................................................................... 8-11

General Back Section ..................................................................................... 8-12

Side Enc. 0 ............................................................................................ 8-12

Side Enc. 3DEG .................................................................................... 8-13

How to select a perfectly square door (or one that’s close enough) ........ 8-14

Feed System ................................................................................................... 8-15

Infeed RH End check: ........................................................................... 8-15

Outfeed LH End check: ........................................................................ 8-16

Infeed Stop: ........................................................................................... 8-16

CHAPTER 9 ..........................................................................................EDGE 9-1

EDGE - Operator’s Tour ......................................................................... 9-3

Control Panel One ................................................................................... 9-4

Control Panel Two .................................................................................. 9-5

Homing the EDGE ........................................................................................... 9-7

Alliance Series

To Home the EDGE ................................................................................ 9-7

Deep Mortise Collet ......................................................................................... 9-9

Tool Insertion .......................................................................................... 9-9

Collet Maintenance ................................................................................. 9-9

CHAPTER 10 ............................................................ Calibrating the EDGE 10-1

How to modify a Parameter: .......................................................................... 10-2

Parameters ...................................................................................................... 10-4

Lock Location .......................................................................................... 10-4

Lock Location RH ................................................................................ 10-4

Loch Location LH ................................................................................. 10-4

Stops ......................................................................................................... 10-5

Left Stop ................................................................................................ 10-5

Middle Stop ........................................................................................... 10-5

Right Stop ............................................................................................. 10-6

Left Outboard Stop ..............................................................................10-6

Right Outboard Stop ............................................................................ 10-7

Deep mortise ............................................................................................ 10-7

DM Vertical ........................................................................................... 10-7

DM Diameter ........................................................................................ 10-8

Deep Mortise X: .................................................................................... 10-8

Depth parameters .................................................................................. 10-8

Plate Router .............................................................................................. 10-9

Router Vert Offset (Vertical Offset) ...................................................... 10-9

Router Diam (Diameter) ....................................................................... 10-9

Depth parameters .................................................................................. 10-9

Counter Rotating Router ........................................................................ 10-10

Cnt Rout Vert, Cnt Rout Horiz (Vertical, Horizontal) ........................ 10-10

Cnt Rout Diam (Counter Router Diameter) ........................................ 10-10

Side Drills .............................................................................................. 10-11

Chisels .................................................................................................... 10-11

Predrills .................................................................................................. 10-12

Predrill 1 X offset and Predrill 1 vert offset ........................................ 10-12

Depth parameter .................................................................................. 10-12

CHAPTER 11 .................................................................................. DL-NCC 11-1

DLNCC - Operator’s Tour ............................................................................. 11-3

Operators Station: .......................................................................................... 11-3

Power ....................................................................................................... 11-3

Touch Screen .................................................................................................. 11-4

Main Screen ............................................................................................. 11-4

Feed ...................................................................................................... 11-4

Alliance Series

Automatic Tool Changer .......................................................................... 11-5

Tool Management ................................................................................. 11-6

Status indicators: ................................................................................... 11-7

Control: ................................................................................................. 11-7

Navigation ............................................................................................. 11-7

Tool Changer ............................................................................................ 11-8

Motor Status .......................................................................................... 11-8

Tool Changer Status .............................................................................. 11-9

Navigation ............................................................................................. 11-9

Manual Run ............................................................................................ 11-10

Feed Controls ...................................................................................... 11-10

Navigation ............................................................................................11-11

Changing a Tool Manually ..................................................................... 11-13

To Change a Tool Manually ................................................................ 11-13

Changing a Tool Bit ............................................................................... 11-14

To Change a Tool Bit .......................................................................... 11-14

Homing the DLNCC .................................................................................... 11-17

To Home the DLNCC ......................................................................... 11-17

CHAPTER 12 .........................................................Calibrating the DL-NCC 12-1

Calibrating the DL-NCC Tool Changer ................................................... 12-1

Determining Which Calibration Stage to Use ...................................... 12-1

Preparing to Calibrate the Tool Changer .............................................. 12-1

Tool Calibration, Stage 1: Calibration Bolt ............................................. 12-3

Tool Calibration, Stage 2: Tool Offset ..................................................... 12-8

Tool Calibration, Stage 3: Tool Holders ................................................ 12-12

Calibrating Cut Accuracy ...................................................................... 12-14

To Calibrate the Cut Accuracy ............................................................ 12-14

Correcting Cut Accuracy Problems ....................................................... 12-17

CHAPTER 13 ........................................................................................RAIL 13-1

Door Stack Access .........................................................................................13-3

To Enable the Door Stack Access Mode: ............................................. 13-3

To Disable the Door Stack Access Mode. ............................................13-4

Rail - Operator’s Tour .................................................................................... 13-5

Operators Station: ..........................................................................................13-6

Control Panel ........................................................................................... 13-6

Touch Screen .................................................................................................. 13-7

OK to Home ............................................................................................. 13-7

Navigation & Control ........................................................................... 13-7

Main Menu REMOTE ............................................................................. 13-8

Feed Control ......................................................................................... 13-8

Alliance Series

Stack Control ........................................................................................ 13-8

Navigation ............................................................................................. 13-9

Main Menu LOCAL .............................................................................. 13-10

Door Length Entry .............................................................................. 13-10

How to change a door length preset: .................................................. 13-11

Entering Fractional Values: ................................................................. 13-12

Feed Control ....................................................................................... 13-12

Stack Control ...................................................................................... 13-12

Navigation ........................................................................................... 13-13

Ready Enter Data ................................................................................ 13-13

How to Run a Door in Manual Local Mode: ......................................... 13-14

Manual Mode ......................................................................................... 13-15

Reset Sequence: .................................................................................. 13-15

Forklift Servo: ..................................................................................... 13-15

Stop Servo: .......................................................................................... 13-15

Carriage Servo: ................................................................................... 13-16

Stack Control ...................................................................................... 13-16

Feed ..................................................................................................... 13-16

Navigation: .......................................................................................... 13-17

Maintenance -1 ...................................................................................... 13-18

Servo Position Points: ......................................................................... 13-18

ModBus Communication mode: ......................................................... 13-18

ModBus Communicating Status: Lift to Rail ..................................... 13-18

Touch Screen Program Version .......................................................... 13-18

Navigation ........................................................................................... 13-19

Troubleshooting .................................................................................. 13-19

Maintenance -2 ...................................................................................... 13-19

Touch Screen view adjustments: ........................................................ 13-19

Navigation: .......................................................................................... 13-19

Remove Door ......................................................................................... 13-20

Feed ..................................................................................................... 13-20

Cross feed system. ............................................................................. 13-20

Clamp: Manual Operation .................................................................. 13-21

Homing Status and Start Button ......................................................... 13-21

Stack Control ...................................................................................... 13-21

Reset Sequence: .................................................................................. 13-21

Machine Data ......................................................................................... 13-22

Technical Support .................................................................................. 13-22

Homing the RAIL ........................................................................................ 13-23

To Home the Rail ................................................................................ 13-23

CHAPTER 14 ...............................................................Calibrating the RAIL 14-1

Alliance Series 1-1

CHAPTER 1 The Alliance Line

This chapter provides over all operating instructions for the KVAL Alliance Line.

The Alliance Line

1-2 Alliance Series

ON-2010

Lift, Flip and Rotate and Stack.

See “ON-2010” on page 3-1 for

operating instructions.

FACE

For small complex cuts on a door’s face.

See “FACE” on page 5-1 for operating

instructions.

Architect DI-DM

For small complex cuts on the hinge and

lock edge of the door.

See “Architect DI-DM” on page 7-1 for

operating instructions.

EDGE

For small complex cuts on the lock edge of

the door.

See “EDGE” on page 9-1 for operating

instructions.

DL-NCC

For large and small complex cuts on a

door’s face.

See “DL-NCC” on page 11-1 for oper-

ating instructions.

RAIL

For small complex cuts on

a door’s top and bottom

edge. plus a stacker.

See “RAIL” on page 13-1

for operating instructions.

Tour of the Line

Alliance Series 1-3

Tour of the Line

1-4 Alliance Series

Quick Start

1.Apply power to the Line.

a.Turn on all compressed lines to all machines.

b.Turn on all electrical disconnects for all machines.

c.Apply electrical power to all Safety Zones starting with Safety Zone one.

Note: Safety Zones must be turned on in order.

Safety Zone 1

Safety Zone 2

Safety Zone 3

Safety Zone 4

d. Pull out the CONTROL TRANSFORMER switch

for each machine in the safety zone.

Each control transformer button should

light and each computer should start.

e. Push the START button for each com-

puter in the safety zone.

All lights on the Status Light Panel for

each machine should be illuminated.

f. If all Safety Zones are powered the Power to the Line

process is complete, if not move to the next safety zone

and go back to step d.

Control

Transformer

Machine

START

STOP

CONTROL

POWER

OVERLOAD

RELAY

E-STOP

STOP

START

24VDC

Quick Start

Alliance Series 1-5

2. Launch the KVAL 2006 user interface

For each machine:

a. Open the KVAL folder on the computer desktop.

b. Double-click the KVAL2006.EXE shortcut. The KVAL 2006 user interface opens (see exam-

ple below).

3. Home each machine:

a. Remove any doors from the feed system.

b. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the

blank button below it to read Home.

c. Click twice on the Home button. The machine should start the homing operation.

d.NOTE:While the homing operation is in progress, the Home button changes its label to

Homing.

4.

Network Off Network On

On each machine toggle the Network ON/OFF button to ON.

The Alliance line is now ready for work.

Maint

Home

OK

Homing

Home?

1-6 Alliance Series

How to load a door stack:

Top View

Door

Stack 1

Stack 2

Stop Door

Stop

Door

Stop Door

Stop

When loading Doors

move doors into the

machine all the way

to the Door Stops.

When loading Doors

move doors into the

machine all the way

to the Door Stops.

Feed

To load doors into the Alliance line:

1. Chose the Door Stack 1 or Door Stack 2 to load based on product flow.

2.Lower the Stack Lift to the desired height. See “Stack Control:” on page 3-10 for more information.

3.Enable the Stack Access mode. See “Door Stack Access” on page 3-3 for more information.

4.Load the doors onto the stack lift. Move the doors into the machine until they doors contact the door

stops.

5.Disable the Stack Access mode. See “Door Stack Access” on page 3-3 for more information.

The doors are now ready to process.

Quick Start

Alliance Series 1-7

Typical Alliance Product flows

Single Stack Feed

Load Doors

Here Remove Doors

Here

Use this mode to process a single door stack.

Dual Stack Feed

Load Doors

Here Remove Doors

Here

Load Doors

Use this mode to process two door stacks.

1-8 Alliance Series

Single Door

Load Doors

Here

Remove Doors

Here

Feed

This mode is typically used for template testing, or for re-processing a door after a a mid-process stream

failure.

External processing

Remove Completed

Doors Here

External

Process

Normal Process Flow

This mode is used for a door that requires additional processing external to the Alliance line.

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Kval face Owner's manual

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