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About Calibration

KVAL Commander III Operation Manual

4-2

About Calibration

Calibration is all about the confidence in the end results of your manufacturing process. Calibra-
tion assures you that your cut parameters are accurate and within the specified limits.

If slight discrepancies in the machining of a door are observed, the built in KVAL calibration can
adjust the tooling to fix the issue.

In troubleshooting, calibration can be an essential step in solving the issue.

About the Calibration Menus and the Calibration Reference Cut

This chapter describes the

Calibration Menus

and to how to perform a

Calibration Reference Cut.

In the

Calibration Menus

, offsets are entered to calibrate assemblies in the machine.

See “About

the Calibration Tabs” on page 4-4.

Before you Calibrate

Before you start calibration, check for the following common issues.

Is the loaded setup correct for the current cut?

Check tools for wear.

Is the correct Calibration loaded?

Are the stops set up correctly?

When did the problem first start? (during a run, at start up, etc)

When was the last calibration?

Is the Door True?

Use Router Bit Depth Gauge (PN: 432C) to check depth.

Check for sawdust build-up, which may affect depth.

Note:

KVAL recommends that a test door is run first and checked for specifications

before a full run is started.

Summary of Contents for Commander III

Page 1: ...Innovation Quality Honesty Commander III Operation Manual With KvalCAM Commander III Door System Operation Manual Published October 6 2020 ...

Page 2: ...ws 7 is a registered trademark of Microsoft Corporation All other products are trademarks or registered trademarks of their respective holders all rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated Contacting KVAL Customer Service For further information about this manual or other Kval Incorpo rated products contact the Custome...

Page 3: ...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 improve ment to userexperience kvalinc com NOTE This is not a customer support email link For that please refer to the Customer Service contact information abov...

Page 4: ...nerated 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 Softwar...

Page 5: ...g Help from KVAL 1 15 On Line Help 1 16 Product Return Procedure 1 16 How to Download the Service Application 1 17 Download Application 1 17 Safety Sign Off Sheet 1 20 A Note to the Operator 1 20 Chapter 2 About KvalCAM About KvalCAM 2 2 Summary of the KvalCAM Interface 2 3 Machine Line 2 3 Libraries 2 3 Machine Control 2 4 About the Libraries 2 5 Distinguish Between the Library Types 2 5 Around t...

Page 6: ...out the Feature Tree Menu 2 20 About the Selected Feature Details Menu 2 21 About the Selected Feature Details Menu Child Level 2 22 About the Control Buttons 2 23 About the Job Preview Screen 2D and 3D 2 24 2 D Screen 2 24 3 D Screen 2 25 About the Machine Line Screen 2 26 Machine Line Screen 2 26 About Backing up Data and Checking the Revision Status 2 30 Job Preview Examples 2 31 Door Face Lock...

Page 7: ...mander III 3 6 Home the Commander III 3 7 How to Power Down the Commander III 3 7 Emergency Shutdown and Recovery 3 8 About Machine Status Feedback 3 9 About the Commander III interface Screens 3 10 Screen Tabs 3 10 About the Main Control Screen 3 11 Machine Controls Section 3 12 About the Main Control Section 3 13 About Sequence Control Section 3 14 About Width Adjust 3 14 About Carriage Control ...

Page 8: ...og Screen 3 34 Description of the Six Light Panel 3 35 Chapter 4 Calibration of Commander III Chapter 4 at a Glance 4 1 About Calibration 4 2 About the Calibration Menus and the Calibration Reference Cut 4 2 Before you Calibrate 4 2 Flow Chart of Calibration 4 3 About the Calibration Tabs 4 4 Access to the Calibration Adjustments 4 4 Unlock the Calibration Option 4 5 How to Enter Calibration Data ...

Page 9: ...bration 4 22 Feed System Timing 4 22 H Block Display and Jamb Adjustments 4 23 Door and Jamb Depth Adjustment Mapping 4 24 Special Options Calibrations 4 26 Thickness Feeler Option 4 26 Thickness Feeler Calibration 4 26 Process to Calibrate Thickness Feelers 4 26 Chapter 5 Tour of the Commander III Operator s Tour 5 2 Top View 5 2 In Feed Section 5 3 Front Section 5 4 About the Operators Station 5...

Page 10: ...KVAL Commander III Manual Table of Contents Option W Lever Lock Drill Function Drill 5 16 Option Thickness Feelers 5 17 Option BC Ball Catch 5 18 Option SJ Split Jamb 5 19 ...

Page 11: ...t IMPORTANT safety information is described in this section page 1 6 Zero Energy to Start Up Procedure to power up your machine for the first time page 1 13 Getting Help from KVAL This section describes the method to contact the KVAL service center for help The section includes how to get information from the specification plate tor provide to KVAL service center hours and return procedures page 1...

Page 12: ...second hinge location A couple of manual adjustments for H blocks and jamb clamps are still necessary but a pointer and setup mode reduce this to under two minutes and eliminates errors Lock Locations fully automatic positioning for lock locations from the door top and up to three locks can processed on one door Program selection for lock hole backsets of 2 3 8 or 2 3 4 and either 1 or 1 1 8 face ...

Page 13: ...achine 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 ...

Page 14: ...l 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 Option Title Description ...

Page 15: ...libration Rou tines and how to use the interfaces 5 Tour of Machine Identification and descriptions of the machine assemblies Chapter Title Description 1 Introduction Safety Information 2 System IT Admin istration Descriptions of the PLC system and computer system 3 Maintenance Maintenance steps for the machine line 4 Troubleshooting Troubleshooting tips and theory of operation Safety Sheet Sign O...

Page 16: ...ogy of Labels In addition to the nameplate KVAL machines may have other warning labels or decals that pro vide safety information to operators Safety labels should be clearly visible to the operator and must be replaced if missing damaged or illegible There are three types of warning labels or decals DANGER means if the danger is not avoided it will cause death or serious injury WARNING means if t...

Page 17: ... 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 ma...

Page 18: ...upply 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 ...

Page 19: ...hine 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 Pr...

Page 20: ...ts etc 2 Inform all affected personnel of the eminent shutdown and the duration of the shut down 3 Obtain locks keys and tags from your employer s lockout center 4 Disconnect power a Turn the disconnect switches on the main electrical panel to the OFF position Then pull out the red tab and place a padlock through the hole Place your tag on the padlock as per the tagout guidelines below see illustr...

Page 21: ...ety 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 lock and tag can now be removed only by the person s who placed them and the machine can be re energized 10 The tags must be destroyed and the locks and keys returned to the lockout center L...

Page 22: ...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 ensure they are in the OFF state ...

Page 23: ...on Please be advised that some com ponents of the machine may start automatically when energy is restored Remove Locks Each operator must remove his or her own lock and tag This will ensure that all oper ators are in a safe place when the equipment is started Perform Visual Checks If the equipment is too large to see all around it station personnel around the area and sound the personnel alarm bef...

Page 24: ...ut procedures work because you are the only one with the key to your lock Proper lockout tagout can save lives limbs and money Help make your work environment safe for you and your fellow workers Be sure to follow the P R O P E R lockout tagout procedures and that those around you do also Close the Cage Gate Verify all cage gates are securely closed Ensure all safety protocols are in effect ...

Page 25: ...pecification Plate and record the serial number 3 phase volts electrical print number and air print number Air Driven Machines 2 Contact our customer support team 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 Email address is service kvalinc com Hours 6 00 AM to 4 00 PM Pacific Standard Time Monday through Thursday 6 30...

Page 26: ...swers to the following questions What is the extent of the failure reason for return What are the relevant error mes sages or error codes How long did it operate Did any other items fail at the same time What was happening when the unit failed e g installing the unit cycling power starting other equipment etc How was the product configured in detail Which if any cables were modified and how With w...

Page 27: ... com 2 At the KVAL website select the Support tab Follow the instruc tions on the Support web page 3 Click the Download button to download the application that allows the KVAL technician to have access to the operator sta tion 4 After the download is com pleted double click the program icon Note Web browsers have different methods of downloading programs Below are samples of i e Explorer and Googl...

Page 28: ...ld Enter your name The KVAL techni cian will use this field to identify this machine Description Enter machine Serial number and issue Indicator Green indicates there is a good connection to the service center If red there could be an issue with a LAN connection Check the connections in the plant 7 After the KVAL Support App is loaded and completed call the KVAL service center 1 800 553 5825 and h...

Page 29: ...How to Download the Service Application 1 19 KVAL Commander III Operation Manual Page Intentionally Left Blank ...

Page 30: ...follow my company s safety procedures I have read and understand these guidelines Machine Safety Concerns I have been given a tour of the machine and understand all the safety labels E Stops and the actions to take in case of an emergency I will make sure all guards are in place before operation I will turn off the compressed air before loading hardware staples screws etc I will turn off the elect...

Page 31: ...tion page 2 2 About the Machine Line Screen Description of the Machine Line Screen Includes Line Control Buttons Queued Jobs and Machine Activity page 2 26 About Backing up Data Instruction to back up data page 2 30 Job Preview Examples Examples of Features in the Job Preview Window page 2 31 About Validation Example of Validation issues page 2 34 About LiteCutout Feature Information about using t...

Page 32: ... downloaded remotely and created at the station The KvalCAM interface uses tabbed navigation to jump to desired screens For more information about KvalCAM and to view a video about KvalCAM go to https kvalinc com Select the KvalCAM feature tab Input Block Diagram KvalCAM has the versatility to connect with many types of inputs A Door Job is built from Door Data and Features The Door Job communicat...

Page 33: ...reen is the boot up screen for KvalCAM View the entire process of the machine line queued jobs quantity and remaining doors and status of each machine Some line control is avail able Libraries The Libraries include three tabs the Door Job Library the Feature Group Library and the Door Data Library At each library screen files can be created edited cloned deleted and downloaded Each Library contain...

Page 34: ...ne has a distinct control screen KvalCAM is purpose built to allow all compatible machinery to communicate with one another Select the desired machine button to take control of that machine Note Information about the Machine Controls is located in the Machine Operation Manual ...

Page 35: ...es Lock editing capabilities and refresh tabs are also available Distinguish Between the Library Types The table below shows the details of the KvalCAM Libraries The Library Screens include The Door Job Library The Door Data Library The Feature Group Library Detail Door Job Door Data Feature Group Saves Cut Information Yes No Yes Saves Door Parameters Yes Yes No Number of Feature Groups Allowed Ma...

Page 36: ...se The Door Job files contains all the information to create a door Files support revisions Around the Door Data Library Screen Below is a list of highlights about this screen Selecting a file from the table leads into the Door Data Creation screen The Door Data Library contains the specifications about an unprocessed door No shape cutting information is at this screen Files can be saved and be at...

Page 37: ...ighlights about this screen Selecting a file from the table leads into the Door Feature Creation screen The Door Feature Library contains shape information There is one shape information per file Files can be saved and be attached to the many Door Job files Files support revisions Tracks variants ...

Page 38: ...cated at each Library Screen Select the Libraries Tab located at the upper left and then select the desired library Note The operations described here are common to all screens Note The Revision Display Panel is hidden Select the line to the right and drag to the left to display this pane FIGURE 2 1 Library Screen ...

Page 39: ...words to search by name or description Select the Display Deleted Check Box to view or recover deleted door files Tip Change the column widths by selecting the column border and dragging to the desired width Using the Display Deleted Check Box Recover a Door File Follow this procedure to recover a door file 1 Select the Display Deleted Check Box located in the upper right hand corner 2 Deleted fil...

Page 40: ...n an existing file to view or edit Edit or view a Door Job Door Feature or Door Data file 1 Select a file from the File Table 2 Select the Edit View Button to go the file screen Tip Double click the desired file in the table to go straight to the screen Using the Clone Button Use the Clone Button to create a copy of a door file To Clone a File 1 Select the file to be cloned from the table 2 Select...

Page 41: ...te Button turns into the Restore Button when the Display Deleted Check Box is selected To Delete a File 1 Select the file to be deleted from the table 2 Select the Delete Button 3 At the pop up window select Yes to delete the file Note To restore a file see Using the Display Deleted Check Box Recover a Door File on page 2 9 Clone Pop Up Screen ...

Page 42: ...e figure below shows two highlighted files to be compared Use the Diff Button to Compare Two Files 1 Select 2 files to compare 2 Select the Diff Button 3 In the popup window the differences are highlighted The top selected file is highlighted in red while the second file selected is highlighted in green ...

Page 43: ...SQL Text Box 3 Select the Connect Button 4 Select the Go to Libraries Button that is located at the bottom of the screen About the Database Screen Contents The database screen contains the following Data Source path PostgreSQL Status Information Connection State Tip If not connected verify path Server Multiple servers may be created Database This is the name assigned to the database User Assigned ...

Page 44: ...contains a Principle and Diff Button The Diff Button compares two files For information about using the Diff Button see Using the Diff Button on page 2 12 Using the Principle Button Normally the top file in the table is the principle However any revised file can be assigned as the principle using the Principle Button 1 From the revision table select to highlight the desired revision file 2 Select ...

Page 45: ... The Door Jobs that contain the selected Door Data File The Revision ID Revisions at the Door Feature Group Library In the upper panel the Door Feature file revisions may be compared and any file can be assigned as the principle The lower panel displays The Door Jobs that contain the selected Feature Group File The Revision ID Any Variant in the files For a Variant definition see Variant on page 2...

Page 46: ...About Revisions 2 16 KVAL Manual ...

Page 47: ... of face lock and hinge job creations are located in this manual See Job Preview Examples on page 2 31 Note For a definition of validation errors see Validation on page 2 50 FIGURE 2 2 Screen Shot of Job Creation To create a new Door Job select the Create button at the bottom of the screen To edit or view a created Door Job select the item from the table then select the Edit View button on the bot...

Page 48: ...ption Add an descrip tion of the Door Job About the Door Data Menu Door Parameters Displays the basic parameters of the door being processed Door Material Select type of material of the Face Hinge side and Lock side of the door Wood Fiber Glass or Steel Name and Description Add a file name and description Door Hand Select the Hand Ori entation of the Door From the drip down menu select Left Hand R...

Page 49: ...About Door Job Creation 2 19 KVAL Manual Breakdown of a Feature Group and Features Feature Groups and Features resemble an outline FIGURE 2 3 Feature Group Breakdown About the Feature Tree Menu ...

Page 50: ...es Add Child Select to create a new child to the Feature or Feature Group Add from Library Select to add a file from the Feature Library Delete Select to delete a Group or Child Notes Tips Color Coded Indicators next to the Child Features are color coded to reflect the location on the door Hinge Edge Lock Edge Hinge Pivot Face Oppo site Hinge Pivot Face Top End Bottom End Validation If a cut is no...

Page 51: ...is example the hinge locations are located 6 75 36 0 and 65 25 with a reference from the top of the door Coordinate References Set the reference in relation with the cut The reference option will be dis played in Job Preview T Thick Reference Hinge Pivot Face Key Face Opposite Key Face Opposite Hinge Pivot Face L Length Reference Bottom Top W Width Reference Lock Hinge Defined Properties Create a ...

Page 52: ...ous page The example below details the parameters of the hinge cut Predrill locations are also included in the example Feature Name Name of The Fea ture Under the Group Feature Type Select type of cut Circle FaceCircle FaceRectangle Hinge Rectangle TeeShape Face Profile LiteCutout See About the LiteCutout Feature Detail DL NCD Only on page 2 37 Door Side Select Door Side Bottom End Top End Hinge E...

Page 53: ...ct to Save all a new Door Job or save Edits to a Job Password Protected Add to Queue and Door Qty The first step of door processing Enter the quantity of doors to be pro cessed in the Door Qty Box then select the Add to Queue button to start the process See About the Machine Line Screen on page 2 26 Save as New Make adjustments to an existing cut pattern and save as another file Export to DXF Sele...

Page 54: ...ew Examples on page 2 31 Display Area Door Axis Axis changes per Preview Surface selections See Axis on page 2 49 Preview Surface Preview Surface Select from drop down list to view Bottom End Top End Hinge Edge Lock Edge Hinge Pivot Face Opposite Pivot Face Grid Lines in Change the size of the grid line Scale Percent Displays the mag nification value of the screen pre view Note May use the mouse w...

Page 55: ...2 25 KVAL Manual 3 D Screen Select the 3 D Tab to display a three dimensional view of the Door Job Right click the mouse to control the movement of the 3 D display The Preview Surfaces are color coded and listed on the display ...

Page 56: ... Select the Machine Line Tab on the left side of the screen to jump to this screen Machine Line Screen Menu Description A Machine Activity For each machine a table shows job name quantity of remain ing doors doors being processed and status of the machine B Queued Jobs Shows a list of the upcoming jobs C Line Controls Common operations to control the machine line ...

Page 57: ...ite Machine is idle Orange Machine is paused Machine Lists the machines in the line Status Lists the status of each machine Quantity Lists the quantity of doors at the start of the Door Job Job Lists the name of the Job being processed The Job name reflects the name assigned in the Door Job Library Remaining Lists remaining quantity of doors left in the Door Job Templates Descrip tion of the types...

Page 58: ... selecting the desired title Sortable Queue Order Lists the jobs that are going to be processed Commands Select the Remove Button to clear the Job from the list Creation Time List the time when the job is put in queue Job List the file name of the Job Quantity Lists the quantity of doors at the start of the Door Job Template List the File name of the Template ...

Page 59: ...achine between Auto Feed ON or Auto Feed OFF Auto Feed ON The door will automat ically feed through each machine Auto Feed OFF The feed status must be set the machine Operator s Screen Clear Queued Jobs Press to clear the entire list of Door Jobs in the Queued Job table Home the Machine Line Press to Home every machine in the line Reset the Machine Line Press to reset the every machine in the line...

Page 60: ... the current build Exit Select to close the running KvalCAM pro gram Release Notes Select to open a PDF of the his tory of release notes on this version o software Backup Select to save the to save all data from the machine operation Notes may be added to describe the saved file Licenses Select to see all third party licenses Kval Docs Website Select to go to a see Kval CAM documentation Must have...

Page 61: ...or lock preview form the face viewpoint Highlight the item from the Feature Tree The Preview Screen will display the cut from the feature group point of view Note the Axis indicator Length and Width for a quick refer ence Note Errors will be indicated by an orange box around the parameter Note Change views by using the manual view buttons at he bottom of the screen Lock Parameters Lock Locations ...

Page 62: ...tem from the Feature Tree The Preview Screen will display the cut from the feature group point of view Note the Axis indicator Length and Width for a quick refer ence Note Errors will be indicated by an orange box around the parameter Note Change views by using the manual view buttons at he bottom of the screen S Lock Parameters and Locations ...

Page 63: ...item from the Feature Tree The Preview Screen will display the cut from the feature group point of view Note the Axis indicator Length and Width for a quick refer ence Note Errors will be indicated by an orange box around the parameter Note Change views by using the manual view buttons at he bottom of the screen Lock Parameters and Locations ...

Page 64: ... Door Job will be highlighted with instructions to fix the error This is a sample of an incorrect depth parameter Validation error is discovered when creat ing a Door Job 1 An Orange Box will highlight the group with an error In this sample the Lock Edge Child has an error 2 To investigate the error select the Vali dation Report button at the bottom of the display 1 2 ...

Page 65: ...KVAL Manual About the Validation Screen The Validation Screen displays a nested outline of the error cause Displays the definitions of an error and definitions of parameter Shows the hierarchical outline of tested parameters ...

Page 66: ...p Each child node is listed under the selected group In this case there is an error in the Lock Edge routine Either change the depth in the table of the Feature Table or select Commander 3 Tool Con fig Lock Tools and change the depth in the Depth Stop Z Loca tion field to match desired depth ...

Page 67: ...t the LiteCutout Screen on page 2 41 To add a new LiteCutout 1 If needed add a Feature Group 2 Add a Child to the Feature Tree 3 Select LiteCutout from the Feature Type drop down menu and add a Feature Name add a Feature Name 4 Select the Edit Button The LiteCutout is a Feature Type selection With this feature type DXF Drawing Exchange For mat files can be imported manipulated on a sep arate scree...

Page 68: ...Only 2 38 KVAL Manual 5 The LiteCutout working space is displayed 6 Select the Import DXF Button and select the desired file from your directory If needed manipulate the shape Add Group Select LiteCutout and Name Add Child Select the Edit Button ...

Page 69: ... Feature Detail DL NCD Only 2 39 KVAL Manual 7 Add the file into KvalCAM by selecting the OK Button 8 Input WLocation and LLocation to put the cut onto the door Import DXF file In this example an oval DXF file was imported ...

Page 70: ...About the LiteCutout Feature Detail DL NCD Only 2 40 KVAL Manual 9 If finished with editing the Door Job run the door ...

Page 71: ...About the LiteCutout Feature Detail DL NCD Only 2 41 KVAL Manual About the LiteCutout Screen This section describes selections on the LiteCutout Screen ...

Page 72: ... machines and doors About the Work Areas Zoom In and Out with Mouse Move shape vertically and horizontally with Slide Bars Select a vertex point on the cutting path and manipulate the shape Expand or collapse windows 0 0 origin point Referenced to the LLocation and WLo cation on the door Y Positive goes toward the Hinge Edge Y Negative goes toward the Lock Edge X Positive goes toward the Top of th...

Page 73: ...ertex Button in the bottom bar Cutting Path Width varies with the MaxToolDiameter size that is inputed Knockout Point Points may be added with the Insert Knock Out Point button located under LiteCutout Parameters menu Plunge Point Point may be adjusted with controls in the LiteCutout Parameter menu or moved manually with the mouse ...

Page 74: ...kground with error descriptions View Setting Control the display settings of the Work Area Selected Details Displays the details of a selected point on the DXF file The Shape may be manipulated with a mouse or by populating the designated input boxes OK Send to KvalCAM Cancel Stop work and go back to KvalCAM Insert Vertex Insert another Vertex point along the cutting path Delete Selected Delete an...

Page 75: ...ing blocks of a Door Job Job Door assigned file name Door Data Door slab specifications Feature Tree A collection of Feature Groups Selected Feature Details Shapes locations and cut information of the features that are part of the Feature Group FIGURE 2 4 Door Job Parts Door Data Door Data represents all the information for a door slab and or jamb Properties such as the door length width thickness...

Page 76: ...tion of Features that describe the operations to be done Feature Groups can be created edited and saved in the Feature Group Library Feature Groups and it s associated Features may be added to a Door Job Figure 2 4 below shows a collection of Feature Groups in a Door Job More information about Feature Groups can be found at About the Feature Tree Menu on page 2 19 FIGURE 2 6 Feature Group Panel ...

Page 77: ...e Selected Feature Details Menu Child Level on page 2 22 FIGURE 2 7 Feature Details Example Revision After editing an existing Door Job Door Data or Feature Group in the KvalCAM library a revision is created Revisions represent a save point in the history of editing the Principle revision is the current save point in the case of Door Data or Feature Group In the case of a Door Job the Princi ple i...

Page 78: ...For example there may be a Feature Group that represents cuts for a particular lock but the loca tion of the lock varies between Door Jobs By adding the lock Feature Group to the Door Job then changing its location and saving the Door Job a modified Variant will be created When looking at the associated Door Jobs of that lock Revision all of the Door Jobs will be listed even if the location varies...

Page 79: ...ision The process to use the Diff function can be found at Using the Diff Button on page 2 12 Axis An axis icon is located on the Door Preview Screen to visually represent the door reference Figure 2 9 below shows the axis icons Note the icon relationship to the door graphic FIGURE 2 9 Axis Icons in Job Preview L Represents the Length axis W Represents the Width Axis T Represents the Thickness Axi...

Page 80: ...preted to a real number for validation while orange appears if the line cannot perform the cut FIGURE 2 10 Example of a Validation Error Indication Validation Report A Validation Report identifies particular faults that would cause a feature to fail validation Each feature has its own validation tests and will fail if the tests for a valid feature are not satisfied Clicking on a specific test will...

Page 81: ...Common Terms 2 51 KVAL Manual FIGURE 2 11 Example of a Validation Report ...

Page 82: ...following information is available in this chapter Section Name Summary Page About the Commander III Process A summary of the Commander iii machining pro cess page 3 2 Quick Start A summary of the steps to machine a door page 3 3 Powering Operations for the Commander III Descriptions of power up power down homing and emergency stops page 3 6 Description of the Operator Interface Each interface scr...

Page 83: ... Go to main screen 4 Make machine adjustments to the displayed values on the main screen if necessary 5 Put in suggested jamb pin 4 inch jamb or greater 6 Insert jamb into machine 7 Push the Start Sequence button Route Lock Route lock Edge Route Hinge on Door and Jamb Manually Attach Hinges Outfeed door InFeed Door Move H Blocks to setting Clamp Insert Jamb Clamp Start Process ...

Page 84: ...ommander III main air supply valve is turned on Power up the Commander III See How to Power Up the Commander III on page 3 6 Select the KvalCAM shortcut to open the KvalCAM pro gram Home the Commander III See Home the Commander III on page 3 7 Select the Libraries Tab at the upper left side of the screen Select the Door Job Library Tab at the upper center screen From the table double click the des...

Page 85: ...rocedure assumes Auto Feed is active 1 Feed in a door from the Door Feeder or table to the Door Stop 2 Ensure Door is set and clamped in machine 3 Place Jamb on the jamb shelf butted against the stop 4 Press Jamb Clamp foot pedal to clamp the jamb Jamb Stop Door Clamps Jamb Clamps ...

Page 86: ... case of Left Hand Doors the Jamb Stop location will be listed as well 5 If needed move the H Block Left edge of block as reference 6 Left Hand Doors If needed move Jamb Stop to the displayed position left edge of block as reference 7 If the current group cut is completed the next group will automatically load 8 If needed move the highlighted H Block 9 If all groups are finished and the Door Finis...

Page 87: ...ll E Stop buttons are out and safety gate door s are closed Note A pop up is displayed on the user screen if an E Stop is pressed The pop up will indicate which E Stop has been activated 3 Make sure the electrical disconnect in the electrical cabinet is turned to the ON position 4 Switch the green CONTROL TRANS FORMER switch to the ON position It should light up 5 Push the green START MACHINE butt...

Page 88: ...I 1 Select the Stop button if machine is running 2 Right click the KVAL Icon at the bottom of the page select Exit from the drop down menu Note Make sure Windows is shutdown completely before turning off the machine Hard drive or data may be damaged if not turned off in this order 3 Switch the green CONTROL TRANSFORMER switch to the OFF position 4 KVAL also recommends that you turn the disconnect ...

Page 89: ...rol or is about to damage personnel or equipment When an E Stop switch is activated power to the machine is killed The machine responds in the same way if you press the STOP button on the operator s station Summary of the KvalCAM Interface The KvalCAM software includes a single User Interface to control the entire machine line Each machine can also be controlled separately or as a collective Door ...

Page 90: ...l machines is displayed The machines are constantly polled feeding back their state of operation This feedback is a great tool to instantly view the status of the machine This information can be used to troubleshoot any issues that may occur When activated the tab will highlight Note At the top of the screen the revision of software is dis played ...

Page 91: ...ls of the Machine For information Manual Servo Control Operate the machine manually by moving the servo motors Tool Config For information see About the Tool Config Tabs on page 3 25 Calibration Refine and calibrated servo driven assemblies See Chapter 3 Tool Path Preview See the paths of the tools by way of an animated display Status For information see About the Status Screen on page 3 33 Log Fo...

Page 92: ... Screen The Main Control Screen is the most utilized screen Information to machine a door is displayed on this screen The illustration below displays a screen without a door loaded from the Door Job menu FIGURE 3 1 Commander III Main Screen Select the Main Control Tab Machine Controls See page 3 12 Machine Feedback and Machine Controls See page 3 17 ...

Page 93: ...n Description A Main Control High level controls of the machine B Sequence Control Control the sequence of the door cut C Width Adjust Control the Width Gates D Feed System Control the Feed in of the door E Carriage Shift Shift the Carriage into pocket and out of pocket F Ball Catch Enable or disable the ball catch function G Speed Control Control the percentage of machine speed ...

Page 94: ...owered up or reset Reset Machine If a fault occurs that cannot be cleared press the Reset Machine button This button will reset the machine to the start position Important Press the Home button after resetting the machine Setup Mode On Off Select Setup Mode to toggle on or off In the On mode a safe mode is active The machine will go through normal sequences except the cutting motors will be inacti...

Page 95: ...this button to toggle to view the setup for the cut Door Finished Indicates when the door is finished with the machining pro cess Auto Width Disable Enable Press to toggle the enable and disable mode of the Auto Width setting In enable mode the machine will auto adjust to the door width when the door is fed into the machine In disable mode the Open and Close buttons become active When Auto Width i...

Page 96: ...erse the feed of the door To stop the feed release the button Forward Press and hold the Forward button to move the door feed forward To stop the feed release the button Normal Speed Press the Normal Speed button once to slow speed To return to previous speed release the button Toggle Clamp Press once to activate Press again to deactivate Toggle Stop Press once to retract the stop Press again to e...

Page 97: ...eed of the cut Press the graduated speeds or select box or enter a desired speed The speed can be changed during real time processing The Ball Catch function drills a hole at the top of the door The ball catch is determined in the Door Job and will be automatically enabled Select to enable or disable if desired ...

Page 98: ...o job name door parameters Group Cut Information A display the number of groups in the door job Task Message A display of the sequence of the door machining B Hinge Task Control Information A display of hinge information C Shelf Pin and Jamb Stop Jamb Stop LH location and Shelf Pin selection D Lock Task Information a display of back section processes Note Depending on machine release machine feed ...

Page 99: ...layed View the H Block setting derived from the Door Job Adjust the H Blocks to the settings Door Job Specs Feedback from the Door Job is displayed Door Job Name KvalCAM Job Name Door Parameters From the Door Job Length Width Thickness Hand LH or RH Current Group Displays the current and number of groups in the Door Job Note Groups are cutting routines that require a setup within the door job Stat...

Page 100: ...o use if enabled To enable or disable all H Blocks select the button located next to the Jamb Pin Configure section Depth Adjust Compen sates for View depth preset values or adjust values for each Hinge H Block Position Indi cates the forecasted position of the H Block See color coding below for actions to take Indicates the H Block needs to be adjusted Indicates the H Block was Found Indicates th...

Page 101: ...ed in Suggested for Mounting Box 2 Enter the pin length value into the Shelf Pin Box 3 Insert the correct pin lengths in the jamb shelfs 2 per H block 4 Process the door Note Make sure pins are removed or changed if processing a door jamb with a a different backset Note Shelf Pin calculations will revert to zero if machine is powered down Note Different size pins can be ordered through KVAL Sales ...

Page 102: ...n gray and no cuts will be made Slow plate Fast Plate toggle button Select to switch between a slow lock or fast lock cutting process on the back section Table X Location The location of the cut on the X Axis part of the door feedback Face Bore Select to enable or disable the face bore Feedback to button includes depth of bore Deep Shallow Function Drill Option Select to enable or disable the func...

Page 103: ...trol Screen From this screen you can control certain functions manually This function is ordinarily used in troubleshooting checking cut specifications and maintenance Select the Manual Servo Control Screen Tab Auto Feed Enable Disable Press to toggle the auto feed of the door ON or OFF Measurement Enable Disable Press to toggle the operation of thickness probe encoder ...

Page 104: ...the servo driven assemblies Press and hold the desired button to move the Lock Head Assem bly in the forward or reverse direction Adjust the speed of the Lock Head assembly to the desired percentage Press and hold the desired button to move the Outfeed Stop in the forward or reverse direc tion Adjust the speed of the Outfeed Stop assembly to the desired percent age ...

Page 105: ...utton to move the Hinge Carriage in the forward or reverse direc tion Adjust the speed of the Hinge Carriage assem bly to the desired percent age Press and hold the desired button to move the Hinge Head Tools in the X Y or Z axises X across the machine Y Up or Down Z In or Out Adjust the speed of the each axis to the desired percentage ...

Page 106: ... The ability to enable or disable specific tool slots The ability to name the tools to familiar names The ability to lock and unlock the ability to enter data To display the Configuration Screen select the Tool Config tab and choose Hinge Tools or Lock Tools At this screen specifications of the tool is entered and saved to the database This information is valuable to compute and provide the most p...

Page 107: ... ton and enter the password in the password popup menu About Using Tool Configuration To Unlock 1 Select the Unlock Button 2 Enter Password in the Pop Up window 3 Click OK 4 The Unlock Button will change to a Lock But ton 5 Tools can now be configured To Lock Select the Lock Button and repeat instruction above 1 Identify the tool that needs replacement Measure the dimensions and capture the data U...

Page 108: ...ion or drill information Each tool can be enabled or disabled About Hinge Tool Configuration Locations of the Tools are shown in the figure below To Disable Select the Enabled Check Box A red line will cross out the tool on the list The tool slot menu will turn red The tool will not operate during the cutting process To Enable Re select the Enabled Check Box ...

Page 109: ...e figure below Note Parameters that are set in these menus are error checked in KvalCAM Validation errors may occur if the settings do not match the Door Job specifications Note Select the Save Button to store any changes made to the parameters Select Save to the store any changes in the parameters Select to burn in a new Chipout Block ...

Page 110: ...dge Bore Set the diameter of the cut and the depth of the cut Depth Diameter Disable or enable the Lock Edge Plate Set the diameter of the cut and the depth of the cut Set the pocket length of lock Set the pocket width of the cut for two different cuts Select to toggle between a 3 Degree or 0 Degree cuts Width Length Depth ...

Page 111: ...enable the Function Drill Select different types of templates that drill lever locks holes See Option W Lever Lock Drill Function Drill on page 5 16 for more information Disable or enable the Face Bore Settings for two cuts Diameter Depth limit and Backset location of Lock Bore Depth Diameter Backset ...

Page 112: ...n Locations of the Ball Catch are shown below Ball Catch Disable or enable the Ball Catch Offset is referenced from the top edge of the door Movable Stop Reference from the door edge to the center of the Ball Catch Hole Backset Edge of door to the Center of the Hole OffSet Top Edge Reference Depth ...

Page 113: ... Library of the Edge SS can be viewed This sequence can be essential if troubleshooting calibrating or checking the wear of a tool Dis crepancies can be viewed before cutting into a door saving product and time The figure below displays a sample of a good Deep Mortise Cut 1 Select a G Code routine form the drop down menu 2 Select the Render Button 3 View the path of the tool on the screen Step 1 S...

Page 114: ...status Status includes a True flag if the assembly is in operation or a False flag if not in operation Also status can include data and motor states idle operation The data can be filtered to observe certain aspects of the operation of the machine This tool is great for troubleshooting to locate faulty assemblies FIGURE 3 2 Status Screen Filter Data Status is listed by Location List of Parameter o...

Page 115: ...r code to machine sections or functions The top line will have the most current routine that is running The codes are color coded Red Error Green Report is a non issue Yellow Warning If the machine issue can not be resolved call KVAL Inc 1 800 553 5825 Have any error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten down time FIGURE 3 3 Log S...

Page 116: ... Glance The following information is available in this chapter Section Name Summary Page About Calibration This Section includes basic information about the cali bration of the machine Such as Overview of the Setup Screens Flow Chart of Calibration Before you Calibrate page 4 1 About the Calibration Routine This section describes the dimensions of the cali bration slot page 4 10 ...

Page 117: ...the Calibration Menus and to how to perform a Calibration Reference Cut In the Calibration Menus offsets are entered to calibrate assemblies in the machine See About the Calibration Tabs on page 4 4 Before you Calibrate Before you start calibration check for the following common issues 1 Is the loaded setup correct for the current cut 2 Check tools for wear 3 Is the correct Calibration loaded 4 Ar...

Page 118: ...alibration 4 3 KVAL Commander III Operation Manual Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the Commander III FIGURE 4 4 Calibration Process Flowchart ...

Page 119: ...ese screens will help localize problem areas Note If the machine issues can not be resolved call KVAL Inc 1 800 553 5825 Have any error code that is displayed ready to give the KVAL representative This will aid in troubleshooting and shorten down time See Getting Help from KVAL on page 1 17 Access to the Calibration Adjustments Buttons to unlock access to calibration save a calibration and restore...

Page 120: ... Calibration Option Access to the calibration is password protected Optional 1 Select the Unlock button 2 At the Password pop up enter the password and select OK to continue 3 The calibration message will change from a red Calibration is Locked to a green Calibration is Unlocked ...

Page 121: ...nstructions to perform a calibration 1 Check for deviations between the expected machining and the actual machining Determine the offset 2 Enter a positive or negative offset in the Offset box to adjust the servos in the X Y and Z directions Note Select the Combine Button to keep track of the offsets during the process 3 After every calibration change select the Save button to store the calibratio...

Page 122: ...tion of the Z axis the thumb represents the positive direction of the Y axis then second finger rep resents the positive the direction of the X axis Axis Direction for Front Section FIGURE 4 6 Left Hand Rule Front Section To create a Restore Point 1 Select the Restore Points button 2 Select the Save Current button from the pop up window save current calibration 3 Name and enter to save To Load or ...

Page 123: ...on Manual 4 8 Axis Direction for Back Section Point at the Back Section from the rear of the machine at the cut of the door FIGURE 4 7 Left Hand Rule Back Section Y X Axis Positive movement Z Axis Positive movement Y Axis Positive movement Z X Y Z X In Feed ...

Page 124: ...outing are at the correct location See Lock Head on page 4 16 If a CNC Back Section is installed see on page 4 27 instead of the Lock Head calibration 6 Repeat steps 2 through 5 above until all parameter are in specification Machine a Left Hand Door The above steps will set a references for a Right Hand Door To set the references for a left hand door use the Out Feed Stop as a reference Note The h...

Page 125: ...e Tools Calibrate each tool separately in the X Y or Z axis see Hinge Tools on page 4 13 Hinge Carriage Location Calibrate the X axis location across the front section see Hinge Car riage Location on page 4 15 Lock Head Calibrate the X axis location across the Lock Head on the back sec tion of the machine Option Thickness encoder calibration is also locat4ed in this section see Lock Head on page 4...

Page 126: ...play and Jamb Adjustments on page 4 23 Jamb Display Adjustment Match the front measuring tape to the display readout see H Block Display and Jamb Adjustments on page 4 23 Door Depth Mappings Adjust the depth of the routing at selected Hinge locations for a batch of untrue doors see Door and Jamb Depth Adjustment Mapping on page 4 24 Jamb Depth Mappings Adjust the depth of Jamb locations for a batc...

Page 127: ... Hinge Head Over All Calibrate the entire Hinge Head with the tools as a set in the X Y and Z axis This calibration is used to center the pocket in the H Block Normally run this calibration if the entire cut pocket is out of specification in location or shape Y Z X Y Z X ...

Page 128: ... axis Normally run this calibration if one of the cut parameters is out of specification For example Chisel corner off center overlapping cut pocket drill holes off center Note First verify that the Hinge Head Over All is calibrated before performing any of these routines Y Z X Y Z X Select the tool to calibrate inde pendently of the carriage ...

Page 129: ... is setup in the correct location 3 Run the hinge 4 After the hinge run is finished check all four corners of the hinge to see if the chis els are in the correct location 5 If the corners of the hinge are out of specification continue the calibration process on the next page Select button to gain access to the Chisel Calibration menu Adjusting the Chisels 1 Identify the corner or comers to be cali...

Page 130: ...sel is too shallow enter it as a positive number d Repeat until chisel position is correct 6 Click the Combine button to combine the two numbers to create reference Hinge Carriage Location Calibrate the Hinge Carriage travel across the front section Normally investigate this if limits of travel of the Head is out of specification a Take the caliper measurement and enter it into the X axis box b If...

Page 131: ...NC back section perform this calibration first then go to on page 4 27 After the CNC calibrations are completed return and perform the Door Stop calibration Calibrate the Lock Head in the X axis Normally investigate this step if the lock routing on the face and edge of the door is out of specification X X ...

Page 132: ... a known good lock cut at a standard 44 000 location on a Right Hand door Once the lock cut is completed check the distance from the top of the door to the center of the lock Note the measurement value X X Option Thickness encoder calibra tion is also located in this section ...

Page 133: ...II machines with this option have added calibrations Note Before performing these calibrations it is suggested to follow the order in Suggested Order of Calibration on page 4 9 Lock Head General Along with the Lock Head General calibration calibrate the Lock Head CNC Tools This routine calibrates the Lock Plate Router in the X Y and Z direction Note Zero and Three degree X and Y are calibrated sep...

Page 134: ... and Z direction The radius of the router cut also may be adjusted X Axis Positive movement Z Axis Positive movement Y Axis Positive movement Run a known good lock plate at a standard location on a Right Hand or Left Hand door Once the lock bore is completed check the distance from the top of the door to the center of the bore hole Note the measurement value Run Calibration until specification is ...

Page 135: ...tion Door Stops These calibrations will set the top of the door references for a right hand and left hand door See graphic on the next page for calibration axis direction Enter a positive or negative number to move the tool in the desired direction X Y Z Positive number moves tools in nega tive number moves tools out Positive Number Negative Number Positive Number Negative Number Upper Right Upper...

Page 136: ... the flow controls are set properly Slow Plate Routine The router time can be adjusted to match the flow control that is mounted on the valve for slow sequence Before adjusting the time make sure the Fast Plate Routine is set properly before adjusting times and flow controls in this section X X X X X The In Feed Stop is the reference for the top of a right hand door The Out Feed Stop is the refere...

Page 137: ... is a delay before the horizontal moves enter a smaller number in this box Horizontal If the Horizontal time is not making it left or right before the vertical move starts enter a larger number This number is in seconds If there is a delay before the vertical moves enter a smaller number in this box Feed System Timing Calibrates the In feed and Out feed timing of the door into the machine Adjust u...

Page 138: ...ion Screens 4 23 KVAL Commander III Operation Manual H Block Display and Jamb Adjustments No servo adjustments are performed in these calibrations This calibration is used ensure the front tape matches the display output ...

Page 139: ... can be made to adjust the hinge depth on one particular pocket Process a Right Hand Door The Depth Mapping is divided into 15 inch sections from 0 to 90 and has a section for over 90 locations 1 Find the position where the hinge is out of specification 2 Note the value of how much the measurement of the out of specification too deep or too shallow 3 Measure from the head of the door and find what...

Page 140: ...the door portion of the menu at 0 15 range Door was set at 0 0000 combined 0 0100 to set at 0 0100 Example 2 The hinge pocket locate at 47 281 on the jamb is 0 0100 shallow To bring back into specification combine 0 0100 into the jamb portion of the menu at the 45 60 range Jamb was set at 0 0100 combined 0 0100 to set at 0 0200 FIGURE 4 5 Fast Lock Plate Timing Menu FIGURE 4 4 Door and Jamb Adjust...

Page 141: ...checked or performed This calibration adjusts the encoders located in on Back Section These calibrations are a starting reference for all calibrations See Special Options Calibrations on page 4 26 for calibration informations Thickness Feeler Calibration Important Setting the Door Feelers is the first calibration that should be checked or performed This calibration adjusts the encoders located in ...

Page 142: ... 7 Check the measurements fed back from the encoder View the Diagnostic Screen 8 Get averages of the feedback Write down the measurements 9 Enter the offsets from the averages and the measured door in the boxes under the Door Width Feelers and Door Length Feelers Menus 10 Enter a negative offset to move the thickness adjust clamps closer 11 Enter a positive offset to move the thickness adjust clam...

Page 143: ...ne page 5 2 Top View A bird s eye view of the machine page 5 2 In Feed Section Identifies assemblies associated with the In Feed page 5 3 Front Section Identifies assemblies associated with the Front Section page 5 4 Operator s Station Key assemblies associated with the Operator s Sta tion page 5 5 Electrical Panels Identifies assemblies Electrical Panels High Volt age warning page 5 10 Six Light ...

Page 144: ...ies of Commander III Operator s Station See About the Operators Station on page 5 5 Hinge Carriage See Hinge Carriage on page 5 6 Electrical Panel 1 and 2 Main and Frequency See About the Electrical Panels on page 5 10 In Feed See In Feed Section on page 5 3 Out Feed See Out Feed on page 5 9 Back Section See Back Section on page 5 7 Front Section See Front Section on page 5 4 Ball Catch X2 See Opt...

Page 145: ...idth adjustment Door is feed through machine for processing FIGURE 5 9 Key Assemblies on the In Feed Section In Feed System Door Enters Machine here Sensors triggered and width is adjusted to door Feed Motor Drives the Door through the machine Movable Gate Adjusts to the width of the door Movable Gate Adjusts to the width of the door ...

Page 146: ...eration Manual 5 4 Front Section The Front Section contains Operator Station Hinge Carriage H Blocks Door Stops Jamb Stop jamb Clamps Operator Station H Block Door Stops Located at In Feed and Out Feed Jamb Clamps Hinge Carriage Jamb Stop ...

Page 147: ...ows communication between the operator and the machine Note See Chapter 2 for Start up information FIGURE 5 10 Operators Station with touch Screen Interface Touch Screen Start Sequence Start cutting Start or Stop Machine Com puter ON or OFF Control Transformer System ON or OFF E Stop Press to Stop all machine functions Controls Keyboard ...

Page 148: ...re Drill Drills pilot holes for insertion of screws on the jamb and the door Counter Rotate Router Routs the hinge pocket on the jamb Works with the Router The CR Router routes in the opposite direction of the Standard Router Provides a cleaner cut Standard Router Routs the hinge pocket on the jamb and the door Chisels Squares the hinge pocket Upper chisels process the pocket on the jamb Lower chi...

Page 149: ... Options on page 5 15 FIGURE 5 12 Key Assemblies on the Back Section Lock Bore Motor and Drill Drills locks holes on the face of the door Bolt Drill Motor Machines lock plate on the side of the door Valve Bank Controls Air Cylinders on back section Feed Belt Feeds Door through Machine Bolt Drill Extend and Retract Cylin der Face Plate Motor and Drill Routs face plate Opt Thickness Feeler ...

Page 150: ...te routing Commander III machines with this option have added calibrations Bolt Drill Motor Machines lock plate on the side of the door Left Lock Plate Chisel Cylinder Squares the edge of the lock plate Right Lock Plate Chisel Cylinder Squares the edge of the lock plate Z Axis Servo Motor Back Section Valve Bank Y Axis Servo Motor X Axis Servo Motor ...

Page 151: ...ut Feed Door is fed to next stage Width is adjustable to Door Movable Gate adjusts to door width Air Filter and Lubricator cleans input air and lubri cates valves Right Hand Indicator Signals that a Right hand door is being out fed Option Door hand indicator light to speed processing in a companion 700C door framer Red Light indicates Right hand door is being out Fed A reset for the 700 C is also ...

Page 152: ...Electrical Panel Supplies voltages to the machine Contains the PLC Programmable Logic Controller Contains servo drives to interact with the servo motors Axis and Lock Location in the front and back sections FIGURE 5 14 Overview of Main Electrical Panel and High Frequency Panel Main Electrical Panel PLC and interface terminals 110 V 24 V Terminals High Voltage Section Input Fuses PDR Motor Connecti...

Page 153: ...te routers width adjust motors and feed motors FIGURE 5 15 Overview of High Frequency Panel High Frequency Panel VFD Section Counter Rotate Hinge Router Hinge Router Pre Drill Router Face Plate Router Width Adjust 110 V 24 V Terminals PLC and interface terminals Control Transformer High Voltage Section Input Fuses PDR PLC and interface terminals Contactor and Thermal Overload Circuits Bolt Drill M...

Page 154: ...II Operation Manual 5 12 Description of the Six Light Panel The six lights on this panel indicate the status of the Commander III system The Sequence that the lights activate is as follows 1 Control Power 2 Overload Relay 3 E Stop 4 Stop 5 Start 6 24VDC ...

Page 155: ...oto Eye 0VDC is sent to the PLC As a result any of the photo detectors output equals 0VDC when a door is sensed Some detectors have an emitter and receiver built in one unit such as an in feed sensor where a door blocks the light and reflects back to the unit Some detectors have an emitter and receiver built in separate units such as the through beam sensor set at a distance from each other If an ...

Page 156: ...l 5 14 The Limit Switch is activated by an assembly moving a switch arm Depending on the model of limit switch the amount of pre travel amount of movement from the arms resting position is either 5 or 20 degrees before the limit switch actuates Clicks Switch Arm ...

Page 157: ...option senses a narrow door at the In Feed of the machine After sensing the door a narrow door fence is engaged and adjusts to the doors width Note The Lock functions is not available with this option Standard Door Sensors Narrow Door Sensors The width of the door is com pared to the Standard Sen sor inputs to activate Narrow Door Fence Pneumatic Con trols for Narrow Door ...

Page 158: ...tor Option W2 Best 93K Cylindrical Gearbox with Airmotor Option W3 Schlage D Serial 792 Drill Gearbox with Airmotor Option W4 Yale 80 7150 0047 010 Drill Gear box with Air motor Option W5 Corbin Russwin VT30458 Drill Gearbox with Airmotor Drill Patterns are stored in the software and can be selected from a drop down list For information on the drop down list see Chapter 2 of this manual To see inf...

Page 159: ...the exact thickness of the door This value is fed back to the on board PLC and is calculated into the process of the door Added features to the interface for this option are located in the Calibration Screen and the Man ual Screen Feeler Location Thickness Feeler Menu Additions Some added features to the interface for this option are located in the Calibration Screen and the Manual Screen The Thic...

Page 160: ...and and right hand doors for drive in ball catches When selected the proper drill automatically pivots in to drill into the top of the door Set the parameters of the Ball Catch at the configuration page Ball Catch Motor and Drill Drills ball catch top edge Out Feed on LH Door Ball Catch Motor and Drill Drills ball catch top edge In Feed on RH Door ...

Page 161: ...un to fire The Start Sequence must have been activated All Jamb Clamps must be activated Safety Senors on the Gun assembly must be triggered Blocked by Jamb To Use this Function 1 Press Start Sequence Button 2 If not already done so load the male split jamb into the female slot of the jamb 3 Load jamb assembly into machine 4 During process press the Fire Side Nailer Button 5 The Stapler Assembly w...

Page 162: ...Options KVAL Commander III Operation Manual 5 20 ...

Page 163: ...ol transformer switch power up3 6 3 7 customer service1 2 D depth adjust calibration4 24 E electrical panels description5 10 emergency shutdown description3 8 F fast lock plate timing calibration4 21 front section key assemblies5 6 G general information about machine1 2 H high frequency panel description5 11 Home Machine3 13 3 18 home the machine3 7 I inductive proximity sensor5 13 in feed section...

Page 164: ...ints create load delete4 7 return material authorization RMA 1 16 returning the product to Kval1 16 Right Hand Rule4 7 Routine Speed Percent3 14 S Safe Mode Enabled Disabled3 13 safety guidelines1 6 Safety Sign Off Sheet Safety Concerns1 20 sensors types5 13 voltage levels5 13 six light panel description3 35 5 12 sequence list3 35 5 12 slow lock plate timing calibration4 23 start machine button po...

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Page 168: ...partment Kval Incorporated 825 Petaluma Boulevard South Petaluma CA 94952 Contacting KVAL 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 Email service kvalinc com http www kvalinc com ...

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