Kval Commander 3 Operating instructions

Type
Operating instructions
Innovation, Quality & Honesty
Operation Manual
Published: 12/22/22
Commander III Operation Manual
With KvalCAM®
Commander III Door System
KVAL Commander III Operation Manual
Proprietary Notice
This manual is confidential and contains proprietary information and intellectual property of Kval
Inc. and is to be used solely by Customer as an operating manual for Kval Inc. machines. Neither
this manual nor any of the information contained herein may be reproduced or disclosed under
any circumstances without the express written permission of Kval Inc. For authorization to copy
this information, please call Kval Technical Support at (800) 553-5825 or fax (707) 762-0485.
Manual Name: Commander III Door System Operation Manual
Manual Revision: 202-MV100.2, 202-MV101.0, 202-MV101.1
Commander III is a trademark of Kval Incorporated.
KvalCAM® is a registered trademark of Kval Incorporated.
Copyright 2022 Kval Incorporated. All rights reserved.
Beckhoff®, TwinCAT®, and EtherCat® are registered trademarks and are licensed by Beckhoff
Automation GmbH
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
For further information about this manual or other Kval Incorporated products, please contact us.
Mailing address:
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
Phone and Fax:
call: (800) 553-5825
fax: (707) 762-0485
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Parts
Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web-
site at the “Contact Us” page.
KVAL Commander III Operation Manual
KVAL Commander III Operation Manual
Technical Support
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Us” page.
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Contact Us” page.
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KVAL Commander III Operation Manual
NOTICE OF OWNERSHIP OF KvalCAM SOFTWARE AND LIMITED LICENSE TO
USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KvalCAM SOFTWARE WHICH OPERATES KVAL
MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED
LICENSE TO USE THE KvalCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.
BY USING THE KvalCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED
LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE
KvalCAM SOFTWARE.
KVAL, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You
are the purchaser of KVAL Machinery operated by the KvalCAM Software are the “Licensee”.
The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM
Software” and further defined herein) which are used in the operation of the KVAL Machinery are licensed, not sold,
to you for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to
you. Licensor retains all ownership of the KvalCAM Software.
Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with KVAL, Inc. The
KvalCAM Software is protected by copyright laws and treaties. Title and related rights in the content generated
through the KvalCAM Software are also the property of the Licensor and are protected by applicable law.
1.
Definitions.
a.“KvalCAM Software” means the KvalCAM computer application installed in the KVAL
Machinery and written documentation and materials provided to you, as well as any revisions or
updates of such computer application and documentation.
b.“Install” means storing of the KvalCAM Software in the computer component of the KVAL
Machinery.
c.“Use” means executing the KvalCAM Software for purpose of operating the KVAL Machin-
ery and use of the documentation for properly operating KvalCAM Software.
2. Grant of License.
a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the Kval-
CAM Software upon payment of all amounts due for the purchase of the related KVAL Machin-
ery.
b.Licensee will make no copies of the KvalCAM Software or alter the KvalCAM Software in
any way. Title to the KvalCAM Software will remain vested in Licensor, and nothing in this
License will give or convey any right, title or interest therein to Licensee except as a licensee.
c.Licensee agrees that it will use the KvalCAM Software or related documentation directly or
indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License
set forth herein.
d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or
disassemble the KvalCAM Software.
e.This License will terminate automatically if Licensee fails to comply with the limitations
described above.
Table of Contents
Commander III
Chapter 1 Introduction to the Commander III
Chapter 1 at a Glance.............................................................. 1-1
Overview of the Commander III System .................................. 1-2
KvalCAM and the Commander III.........................................................1-2
Standard Features................................................................................1-2
Additional Features...............................................................................1-3
Table of Options...................................................................................1-4
bout this Manual ...................................................................................1-5
Operation Manual .................................................................................1-5
Service Manual.....................................................................................1-5
KvalCAM Reference Manual ................................................................1-6
Safety Sheet Sign-Off Sheet.................................................................1-6
Safety First!.............................................................................. 1-7
Safety Sheet Sign-Off Sheet.................................................................1-7
Safety Terminology of Labels................................................................1-7
Safety Guidelines..................................................................................1-7
Lockout-Tagout Guidelines ...................................................... 1-11
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-11
Lockout Tagout Procedure....................................................... 1-12
Pre-Steps Before Lockout Tagout.......................................................1-12
Lockout Tagout Power ........................................................................1-12
Lockout Tagout Air Supply ..................................................................1-13
Start Maintenance...............................................................................1-13
Post Maintenance Steps.....................................................................1-13
Zero-Energy to Start-Up .......................................................... 1-14
Zero-Energy State to Start-Up to Operating State..............................1-14
Getting Help from Kval............................................................. 1-16
Kval Return and Warranty Policy............................................. 1-17
Send the Item .....................................................................................1-17
Acceptance of Return .........................................................................1-17
Refund Turnaround Time ....................................................................1-17
Kval Errors..........................................................................................1-17
Customer Errors .................................................................................1-18
Shipper Errors.....................................................................................1-18
Warranty Replacement Parts..............................................................1-18
Safety Sign-Off Sheet .............................................................. 1-20
A Note to the Operator:.......................................................................1-20
Chapter 2 Operation of the Commander III
Commander III
Table of Contents
About the Commander III Process........................................... 2-2
Summary of Machining a Door ................................................ 2-3
Start the Process ..................................................................................2-3
Load Door Job from KvalCAM..............................................................2-3
Load Door.............................................................................................2-4
Set-Up Front Section and Machine the Door........................................2-5
Powering Operations for the Commander III ........................... 2-6
How to Power Up the Commander III...................................................2-6
Home the Commander III .................................................................... 2-7
How to Power Down the Commander III ..............................................2-7
Emergency Shutdown and Recovery ...................................................2-8
About Machine Status Feedback............................................. 2-9
Summary of the KvalCAM Interface ........................................ 2-10
Libraries and Machine Line Screens ..................................................2-10
Screen Tabs........................................................................................2-10
About the Main Control Screen................................................ 2-11
Machine Controls Section........................................................ 2-12
About the Main Control Section..........................................................2-13
About Sequence Control Section........................................................2-14
About Width Adjust .............................................................................2-14
About Carriage Control.......................................................................2-15
About Ball Catch.................................................................................2-16
About Speed Control ..........................................................................2-16
Machine Feedback and Machine Controls .............................. 2-17
About the Top Feedback Bar ..............................................................2-18
About Hinge Tasks Control .................................................................2-18
Hinge Block Descriptions....................................................................2-19
About the Background Colors.............................................................2-19
Shelf Pin Configure and Jamb Stop Section.......................................2-20
Hinge Section Enable or Disable........................................................2-20
Jamb Stop................................................................................................................ 2-21
Jamb Stop Spacers ............................................................................2-21
About the Manual Servo Control Screen ................................. 2-23
Manual Servo Control.........................................................................2-24
Lock Head Movement.........................................................................2-24
Outfeed Stop.......................................................................................2-25
Hinge Carriage....................................................................................2-25
Hinge Head Movement.......................................................................2-26
About the Tool Config Tabs...................................................... 2-27
Unlock the Tool Slot Configuration......................................................2-28
Table of Contents
Commander III
About Using Tool Configuration ..........................................................2-28
Enable or Disable Tool........................................................................2-29
About Hinge Tool Configuration ............................................... 2-30
Tool Config Parameter Definitions ......................................................2-30
About Lock Tool Configuration................................................. 2-32
Summary of the Lock Tool Config.......................................................2-32
About the Lock Edge Bore Config ......................................................2-33
About the Lock Edge Plate Config......................................................2-33
About the Function Drills Config .........................................................2-34
About the Face Bore Config ...............................................................2-34
About the Burn Chipout Buttons .........................................................2-35
About the Ball Catch Configuration.......................................... 2-36
About the Tool Path Preview Test Screen................................ 2-37
About the Status Screen.......................................................... 2-38
About the Log Screen.............................................................. 2-39
Chapter 3 Calibration of Commander III
Chapter 3 at a Glance.............................................................. 3-1
About Calibration ..................................................................... 3-2
About the Calibration Menus and the Calibration Reference Cut.........3-2
Before you Calibrate.............................................................................3-2
Flow Chart of Calibration .....................................................................3-3
About the Calibration Tabs....................................................... 3-4
Access to the Calibration Adjustments .................................................3-4
Unlock the Calibration (Option).............................................................3-5
How to Enter Calibration Data ................................................. 3-6
About The Calibration Box....................................................................3-6
About Restore Points............................................................................3-7
Enter a Positive or Negative Number? .................................................3-7
Axis Direction for Front Section ............................................................3-7
Axis Direction for Back Section.............................................................3-8
Suggested Order of Calibration ............................................... 3-9
Start with a Right Hand Door................................................................3-9
Machine a Left Hand Door....................................................................3-9
About the Calibration Screens ................................................. 3-10
Summary of Calibrations ....................................................................3-10
Opt FC Added Calibrations .................................................................3-11
Summary of Calibrations for Opt FC...................................................3-11
Commander III
Table of Contents
Hinge Head (Over All).........................................................................3-12
Hinge Tools .........................................................................................3-13
Chisels Calibration..............................................................................3-14
Hinge Carriage Location.....................................................................3-16
Lock Head...........................................................................................3-17
Opt FC: Commander III Faceplate and Chisel Calibrations................3-18
Lock Head General.............................................................................3-18
Axis Calibration Direction....................................................................3-19
Plate Router Calibration (Back Section) .............................................3-19
Chisel Calibration (Back Section) .......................................................3-20
Door Stops..........................................................................................3-20
Fast and Slow Lock Plate Timing........................................................3-21
About Lock Plate Timing Calibration...................................................3-22
Feed System Timing...........................................................................3-22
H-Block Display and Jamb Adjustments .............................................3-23
Door and Jamb Depth Adjustment Mapping .......................................3-24
Special Options (Calibrations) ................................................. 3-26
Thickness Feeler Option.....................................................................3-26
Thickness Feeler Calibration ..............................................................3-26
Process to Calibrate Thickness Feelers .............................................3-26
Chapter 4 Tour of the Commander III
Operator’s Tour ........................................................................ 4-2
Top View ...............................................................................................4-2
In-Feed Section: ...................................................................................4-3
Front Section ........................................................................................4-4
About the Operators Station ................................................................4-5
Hinge Carriage......................................................................................4-6
Back Section:........................................................................................4-7
Option FC: CNC Faceplate and Chisels...............................................4-8
Out-Feed:..............................................................................................4-9
About the Electrical Panels...................................................... 4-10
The Main Electrical Panel:..................................................................4-10
The High Frequency Panel.................................................................4-11
About the Nodes ...................................................................... 4-12
Typical Block Diagram of Network Connections .................................4-12
Graphical Sample of Node Connections and Power Distribution .......4-13
Description of the Light Tower ................................................ 4-14
About Switches and Sensors................................................... 4-15
Options .................................................................................... 4-17
Table of Contents
Commander III
Option ND: Narrow Door Fence..........................................................4-17
Option W: Lever Lock Drill (Function Drill)..........................................4-18
Option: Thickness Feelers ..................................................................4-19
Option BC: Ball Catch.........................................................................4-20
Option SJ: Split Jamb .........................................................................4-21
Commander III
Table of Contents
Chapter 1 at a Glance
1-1
KVAL Commander III Operation Manual
CHAPTER 1 Introduction to the Commander III
This chapter provides an overview of the Kval Commander III System and important safety infor-
mation to follow when operating the machine.
Chapter 1 at a Glance
The following information is available in this chapter
Section Name Summary Page
Overview of the
Commander III
System
This section provides an overview of the Commander
III. It includes a general description and a table of
available options
page 1-2
Safety First! IMPORTANT safety information is described in this
section
page 1-7
Zero-Energy to Start-
Up
Procedure to power up your machine for the first time. page 1-14
Getting Help from
Kval
This section describes the method to contact the Kval
service center for help. The section includes how to
get information from the specification plate tor provide
to Kval, service center hours, and return procedures
page 1-16
Safety Sign-Off Sheet A record to track operators that are trained on the
machine.
page 1-20
Overview of the Commander III System
KVAL Commander III Operation Manual
1-2
Overview of the Commander III System
The Commander III redefines door and jamb machining flexibility, bridging both residential and
commercial markets. Leveraging our revolutionary KvalCAM® software and Beckhoff hardware,
combined with 6-axis movement, the Commander III provides on-going return for facilities need-
ing to increase capacity and processing capability.
KvalCAM, proprietary door-machinery software, provides auto G-Code generation, complete
machine-line integration, and an intelligent scalable database spanning unlimited KvalCAM
machine lines and even facilities.
Auto G-Code generation enables engineers or operators to easily create template files for a wide
variety of hardware by shape, dimension, and location. Eradicating the need for sophisticated pro-
gramming, customers can increase product offering, inventory turnover, and expand market share
while reducing overhead cost.
Machine-line integration is accomplished by one central control system (KvalCAM) recognizing
each machine’s individual capability within the line and simultaneously assigning tasks to each
piece of equipment from one job or template file. As an end user this simulates a “single machine”
with the output and productivity gains of utilizing multiple machines. Template files can be cre-
ated remotely i.e engineering department, and sent to the machine-line queue for the operator to
select. Additionally, machine can be fed by way of the KvalCAM Barcode Mapper application.
KvalCAM and the Commander III
• Allows effortless creation and processing of new door-hardware templates i.e con-
cealed hinges
• Can process an array of strike and hinge jamb hardware with CNC capability using
front section.
• Mirror functionality allows doors to be processed right or left hand while maintain-
ing sill leading always; never need to rotate for door machining.
• Complete integration with other KvalCAM machines
• -Up to date with Kval’s latest superior technology; continuous updates available as
R&D continues.
*Barcode capable with KvalCAM Barcode Mapper purchase
Standard Features
Hinge Head – dual spindle routers with counter rotation for clean entry and exit at
hinge corners (eliminates traditional chip-outs), programmable point to point drill
for screw pilot holes, and corner square chisels for door and jamb. Full X, Y and Z
axis programming is combined with precision ball screws and servo motors. Auto
tilt between a three degree door edge and jamb clamped in the square H blocks so
both can be processed simultaneously, as well as auto detect for jamb only and door
only processing without wasted motions.
Hinge Centers – no collar bars - automatic adjustment with precision encoder sys-
tem combined with a servo motor drive and position lock. The traditional chain and
Overview of the Commander III System
1-3
KVAL Commander III Operation Manual
torque limiter is now a ball screw so an operator can fasten the first hinge after the
hinge head shifts to the second hinge location. A couple of manual adjustments for
H blocks and jamb clamps are still necessary, but a pointer and setup mode reduce
this to under two minutes and eliminates errors.
Lock Locations – fully automatic positioning for lock locations from the door top,
and up to three locks can processed on one door. Program allows operator to change
between two auto-selections for lock-hole backsets (2-3/8” or 2-3/4”) and Face Plate
widths (1” or 1-1/8”). Zero or three degree bevel can be accommodated with
mechanical adjustment via turret. Up to 5” backset and up to 1-1/4” x 12” face plates
can be manually adjusted. Option FC adds corner squaring and full CNC control of
face plate routing.
Door Reference Stops – fully automatic positioning of off-feed door stop to match
door length and hinge off-set with a ball screw and servo motor. The infeed stop is
fixed and is the zero reference for all other settings.
KvalCAM and Beckhoff Control System – integrated components including all Beck-
hoff servo motor and drives. This makes remote support and program updates easier
than ever before. A connection to the internet is required for remote support from
Kval, which can remain physically disconnected except when needed. Software is
pre-installed to monitor all machine functions from our offices in Petaluma when
required.
Additional Features
• Efficient hinge and lock dust take-off connections.
• Auto width adjust to match incoming door widths 18" - 48", or 12" to 48" with
Option ND.
• Door feed system with parallel non-marking belts and heavy duty AC drive for
smooth speed transitions at door reference stops.
• 5 HP lock bore, and 3 HP latch bore with precision Acuflex collets and nuts.
• Auto door clamp.
• Air blow-off to clean the face as the door off-feeds.
• Door hand indicator light to speed processing in a companion 700-C Door Framer.
Overview of the Commander III System
KVAL Commander III Operation Manual
1-4
Table of Options
Option Title Description
Option
AH
Reverse Feeds Facing the hinge routing head, the normal direction is
left to right. This option reverses the feed direction to
feed from right to left.
Option
AR
Architectural Door Package Adds a barcode scanner and processing for architec-
tural doors up 2-1/4” thick., which integrates with the
machine’s industrial PC and CNC positioning motors
to completely automate hinge, pattern processing
and lock locations. Door files can be created with the
software which can reference barcode labels, or be
selected from an on screen list for nearly instant
machine set-up. The door files hare identical to those
used in the Kval Face, Edge and DLNC series
machines so one file can be created to be used in
multiple operations. Anti-Static air blow bar to clean
door face is also included in this package.
Option
FC
CNC Lock Face Plate with Chis-
els
Only available in combination with option AR. Adds
CNC control of face plate routing and corner squaring
of face plates. Includes programming and three addi-
tional servo motors, ball screws, drives and four cor-
ner square chisels. Plate size is limited to a maximum
size 1-1/4” x 6”. Adjustment for zero or three degrees
routing is automatic, but chisels mechanically posi-
tioned for three degree plates only
Option
W
Drill Gearbox and Air Motor Adds the ability to also drill holes for lever locks with
geared drill boxes. The drills operate at the same
time as the 2-1/8 bore and do not affect cycle time.
Each drilling pattern requires a different gear box, fit-
ted with a direct coupled air motor which are priced
below. With the direct coupled design, door width
minimum is 18". Changeover from one pattern to
another takes approximately 5 minutes.
Option
W1
Sargent 4375C Drill Gearbox
with Air motor
See Above (Option W)
Option
W2
Best 93K (Cylindrical) Gearbox
with Air motor
See Above (Option W)
Option
W3
Schlage “D” Serial #792 Drill
Gearbox with Air motor
See Above (Option W)
Option
W4
Yale 80-7150-0047-010 Drill
Gearbox with Air motor
See Above (Option W)
Option
W5
Corbin/Russwin (VT30458) Drill
Gearbox with Airmotor
See Above (Option W)
Overview of the Commander III System
1-5
KVAL Commander III Operation Manual
bout this Manual
This manual is part of a package delivered with the machine line.
Operation Manual
Operation Manual includes the following:
Service Manual
Service Manual includes the following
Chapter Title Description
1Introduction Descriptions of Machine Line and
Safety Information.
2
Operation Inter-
face
Descriptions of how to power
machine line, and operator inter-
face user screens.
3Calibration Descriptions of Calibration Rou-
tines and how to use the interfaces
4
Tour of Com-
mander 3
Identification and descriptions of
the Commander 3 machine assem-
blies.
Chapter Title Description
1Introduction Safety Information.
2System IT Admin-
istration
Descriptions of the PLC system,
and computer system.
3Maintenance Maintenance steps for the
machine line
4Trouble Shooting Troubleshooting tips and theory of
operation.
Overview of the Commander III System
KVAL Commander III Operation Manual
1-6
KvalCAM Reference Manual
KvalCAM Reference Manual includes the following
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-20.
Chapter Title Description
1KvalCAM reference Description of the Interface
2KvalCAM Examples Examples of Common Door Job
Features
3KvalCAM Common
Terms
Common terms associated with
KvalCAM
Safety First!
1-7
KVAL Commander III Operation Manual
Safety First!
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-20.
Safety Terminology of Labels
In addition to the nameplate, Kval machines may have other warning labels or decals that provide
safety information to operators. Safety labels should be clearly visible to the operator and must be
replaced if missing, damaged, or illegible.
There are three types of warning labels or decals:
DANGER means if the danger is not avoided, it will cause death or serious injury.
WARNING means if the warning is not heeded, it can cause death or serious
injury.
CAUTION means if the precaution is not taken, it may cause minor or moderate
injury.
Safety Guidelines
In addition to the caution and warning labels affixed to this machine, follow the guidelines below
to help ensure the safety of equipment and personnel.
This machine is a powerful electro-mechanical motion control
system. You should test your motion system for safety under
all potential conditions. Failure to do so can result in dam-
age to equipment and/or serious injury to personnel.
Ensure that all employees who operate this machine
are aware of and adhere to all safety precautions
posted on the machine and are trained to operate this
machine in a safe manner.
Training
Safety First!
KVAL Commander III Operation Manual
1-8
Never operate the machine without proper eye and
ear protection.
Protective Gear
Never reach hands beyond safety cage. Servo
motors can unexpectedly move quickly.
Never clear screws or hinges out of the machine
while it is running.
Never reach into the router area to retrieve a
hinge. The router may still be running down
after shut down.
Never perform any maintenance unless machine
is at zero state.
Never clean the machine while it is running.
Never walk away from the machine while it is
running.
When the Machine is ON
The compressed air system connected to this
machine should have a three-way air valve
for shut-off and pressure relief.
All cylinders on machine are under high
pressure and can be very dangerous when
activated. Before performing any mainte-
nance or repairs on this machine turn off the
main air disconnect. Lockout and tagout
this connection.
See “Lockout-Tagout Guidelines” on
page 1-11.
Compressed Air
Safety First!
1-9
KVAL Commander III Operation Manual
Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, you must install an
approved disconnect for the
electrical power supplying this
machine.
When opening the cabinet you must first turn off the
disconnect switch. When the cabinet door is open there
is still power on the top side of the disconnect switch.
Some machines are powered by more than one supply
located at different locations. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
Prior to performing any maintenance, repairs,
cleaning or when clearing jammed debris, you
must disconnect, tag out, or lock out the elec-
trical and air pressure systems. This should be
done in accordance with applicable state and/
or federal code requirements.
Before Conducting Maintenance
Safety First!
KVAL Commander III Operation Manual
1-10
Kval advises that you request an on-site state
safety review of your installation of this
machine. This is to ensure conformance to any
additional specific safety and health regula-
tions which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP pro-
duction. It is your responsibility to immediately protect
your employees against any such hazard.
Additional detailed safety guidelines are included in the
operating instructions of this manual. Kval will be
pleased to review with you any questions you may have
regarding the safe operation of this machine
Follow Your Company’s Safety Procedures
In addition to these safety guidelines. Your company
should have on-site and machine specific safety proce-
dures to follow.
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Kval Commander 3 Operating instructions

Type
Operating instructions

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