Kval Commander Instruction Manual Download

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REV.1

KVAL INC.

INSTRUCTION MANUAL

Commander

Door Pre-Hanging Machine

Summary of Contents for Commander

Page 1: ...REV 1 KVAL INC INSTRUCTION MANUAL Commander DoorPre HangingMachine ...

Page 2: ...1 ...

Page 3: ... FAST and SAFE production as soon as possible It is very important that all OPERATORS and MAINTENANCE personnel read this manual thoroughly We have included important safety information that will help prevent serious injury as well as complete maintenance and troubleshooting instructions Proper operation and maintenance of your new KVAL machine will guarantee many years of trouble free fast paced ...

Page 4: ... rights reserved Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated Proprietary Notice This document contains confidential and trade secret information which is proprietary to Kval Inc Kval and is protected by laws pertaining to such materials This document the information in this document and all rights there to are the sole and exclusive pro...

Page 5: ...ON 13 SPECIFICATIONS 15 UNCRATING THE COMMANDER 16 COMMANDER INSTALLATION 16 REMOUNTING COMPONENTS 16 BOLTING THE OPTIONAL 555 DOOR SIZER 16 LEVELING THE COMMANDER AND THE OPTIONAL 555 DOOR SIZER 16 ELECTRICAL HOOK UP 16 ROTATION CHECK 16 ANCHORING THE MACHINE TO THE FLOOR 19 MAINTENANCE SCHEDULE FOR COMMANDER 21 DAILY 21 WEEKLY 21 MAY AND DECEMBER CHECK UPS 21 LUBRICATION REQUIREMENTS 23 Linear B...

Page 6: ... OPTIONAL 29 FEED MODE OPTION 29 AUTO IN 29 AUTO IN OUT 29 Door Only 29 Door Jamb 29 FEED OPTION 29 JOG FWD 29 JOG REV 29 START SEQUENCE FRONT BACK OPTION 29 FRONT 29 BACK 29 FRONT SECTION 31 COMMANDER HINGE SECTION 31 HINGE LOCATIONS 31 STANDARD HINGE CENTER SET UP 31 SETTING THE OFF FEED STOP 31 HINGE SIZE 32 HINGE BACKSET DOOR 32 HINGE BACKSET JAMB 32 EXTERIOR DOORS 32 CHANGING CHIPOUT BLOCKS 3...

Page 7: ...AL TROUBLE SHOOTING 53 IF THE POWER STOPS DURING NORMAL OPERATIONS DE ENERGIZED 53 FRONT SECTION DOES NOT FUNCTION PROPERLY 55 FRONT SECTION IS NOT TURNED ON AT THE CONTROL PANEL 55 THE SIX SHOOTER IS NOT MOVED FULLY TO THE RIGHT 55 THE THROUGH BEAM LENSES ARE DIRTY 55 SOMETHING IS WRONG WITH THE CYLINDERS THAT MOVE THE FRONT SECTION 57 MOVE FRONT SECTION TO THE IN POCKET POSITION THEN DO THE FOLL...

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Page 9: ...n KVAL is happy to help its customer make the most of their investment and help solve any problems that may occur When you call please have the electrical print air print number and the serial number of the machine ready so that we are able to accommodate your needs efficiently HOURS 6 30 AM to 4 30PM Pacific Standard Time Monday thru Friday Phone 707 762 7367 Fax 707 762 0485 www kvalinc com Chap...

Page 10: ...rns are subject to 15 Re stocking Charge When you call 1 Have your Packing Slip and or invoice s available 2 Have reason for return available When sending merchandise back 1 Make sure that the Item s you are returning are securely packaged and well protected from shipping damage 2 Including Packing Slip 3 Include your RMA on the outside of the package so our shipping receiver will see it Kval trie...

Page 11: ...achine has set collars to secure the moveable assembly mounted to the shafts 4 Take off any tape securing the various buttons switches and knobs 5 Level your KVAL machine by putting metal shims underneath the corners of the base Leave a clear shot from the bolt holes in the foot pads to your shop floor Now make sure the machine won t rock back and forth 6 Once the machine is level anchor it to the...

Page 12: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 4 ...

Page 13: ... be duplicated or disclosed to unauthorized persons 5 SafetyFirstDanger This section contains important safety information Failure to follow these safety guidelines may subject the operator to physical hazards that may result in serious bodily arm or death Chapter 2 ...

Page 14: ...e main source s of energy must be disconnected as well Also ensure that all mechanically stored energy has been released i e lifting booms lowered to bottom of travel carriages in HOME position etc No one may remove a tag or lock installed by someone else Only the person who attached the tag or lock is authorized to remove it 5 Once the lock and tag is in place the employee must try to operate the...

Page 15: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 7 LockoutandTagOutProcedure ...

Page 16: ...and or Pneumatic Energy 3 Fluids and Gases 4 Mechanical Energy ACCIDENT SITUATIONS Accident Start Up Equipment can accidentally be turned on and your hands may be in the point of operation or while you are inside Electrical Shock You can be accidentally electrocuted if the power is still on or if it is accidentally turned on Hazardous Materials If released can go into confined areas or the work ar...

Page 17: ... need to sign the tag 4 One Key Per Lock 5 Never give your key to anyone else Recheck controls and return to proper setting P R O P E R ELECTRICAL LOCK OUT P Process Shut Down Open disconnect before pulling the plug Shut down process or equipment R Recognize Energy Type Recognize the correct power source O Off Shut Off all Power Controls Shut off machine and electrical energy at both machine and m...

Page 18: ...ods Keep in mind that when bleeding stored energy it could cause some parts of the equipment to move as it is being held by the stored energy R Recheck Controls and Return To OFF Setting Return controls to proper settings P R O P E R FLUIDS AND GASES LOCK OUT P Process Shut Down Shut down process using recommended procedures R Recognize Energy Type Recognize the material and its hazards If materia...

Page 19: ...ical energy can also be stored 1 Gravity Things that are up can fall of their own weight Pins or blocking may be required 2 Springs BOING can spell DEATH Release tension or compressed springs by using methods prescribed by the equipment manufacturer 3 Tensions Things under tension can spring in Release tension by using prescribed method by equipment manufacturer P Process Shut Down Shut down the p...

Page 20: ... station personnel around the area and sound the personnel alarm before starting the equipment If your operation is more complex having many pieces of equipment and a lot of people a comprehensive Lock Out Tag Out procedure may involve additional steps You will need to ask your supervisor about these procedures A specific lock out procedure may be posted at each machine On larger or long term main...

Page 21: ...ODES AND REGULATIONS It is advised that you request an on site State safety review of your installation of this machine This is to ensure conformance to any additional specific safety and health regulations which apply in your area OPERATORS TRAINING You must ensure that all operators of this machine be trained to know the potential electrical hazards pressure pinch points rotating cutters and oth...

Page 22: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 14 ...

Page 23: ...k with a 5 8 stop or 1 7 8 thick overall There is no limitation on jamb width Hinge Routing Automatic hinge routing unit accommodates both and 5 8 radius hinges up to 5 1 2 utilizing turret stop adjustments Hinge centers are adjusted by positioning collars on a removable plug in shaft below the router and sliding jamb clamping fixtures into position Extra shafts may be set up and plugged in for ra...

Page 24: ...ng a licensed electrical contractor to hook the machine into your buildings electrical system Code approved circuit interruption equipment and lockable wall mounted disconnects are necessary for both the single and three phase services otherwise the service wires connected to the main panel on the backside of the Commander will not shut off for maintenance or repair work Amperage varies depending ...

Page 25: ...mmander Air should be supplied inside the left rear leg to the Filter Regulator Lubricator module Once the machine is up and running sight through the glass on top of the lubricator and turn the adjustment screw so one drop every two cycles is fed to the system Check the filter bow daily and empty if its more than half full of water Finally if your plant is located in a humid area we recommend a a...

Page 26: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 18 ...

Page 27: ...e walls of the holes Insert anchors through the mounting holes in the foot pads and into the holes you have drilled into the concrete If an anchor s expansion sleeve binds inside the hole simply tap the bolt head with a hammer until the binding stops Tighten bolts until they are snug Avoid over tightening the bolt as this may cause the head of the bolt to break Anchoring Instructions using Epoxy W...

Page 28: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 20 ...

Page 29: ...s Check Check the air filter water trap Empty if full Weekly Preventive Maintenance Op Operation Description Check Check the machine for smooth motion through a complete door cycle Clean Clean linear bearings and the chrome shaft with a clean dry cloth then lubricate Check Check all air lines electrical wiring for kinks or rubbing LUBE Refill lubricator with an ISO 32 standard hydraulic oil KVAL p...

Page 30: ...ra Lith Grease KVAL P N Lube EP 2 Pillow Block Bearing Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Air Line Lubricator One drop of oil every 2 or 3 cycles Check the lines every week to two weeks Either lubricant listed below is approved to use KVAL P N SYSLUBG Chevron AW Hydraulic Oil 32 G C lubricants light AW R O Mobile DTE 24 Shell Tellus32 Gulf Harmony 32 Gear Box 2000 ...

Page 31: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 22 ...

Page 32: ...uency Motors Spindle motor s are installed pre lubricated For re lubrication use lithium based NLGI grade 2 grease The only greases currently approved for use in Perske motors are Optimol Longtime PD2 or LDS 18 Special A KVAL P N LUBE PD2 Failure to use the approved products voids warranty Approved Lubrication Products Chevron AW Hydraulic Oil 32 or KVAL P N SYSLUBG or G C lubricants light AW R O ...

Page 33: ...machine lubricator to insure that it is putting the proper dose of oil in the air lines Usually 1 drop every 3 4 cycles is a good rule of thumb To prime the lubricator find an air line on the Front Section of the machine that is energized and disconnect it allowing the air stream to bleed air pressure away from any persons Direct the air stream at the machine so you can see when there is an oily f...

Page 34: ...not to be duplicated or disclosed to unauthorized persons 25 ZERK FITTINGS Figure 2 This shows how to adjust the lubricators and shows the air lock out valves 1 drop every 3 4 cycles ZERK fitting ZERK fitting depending on the position of the slide ZERK fitting ...

Page 35: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 26 ...

Page 36: ...ed on the left end of the commander Unclamp the machine using the Door Clamp Pedal Turn the door width adjustment drum switch while watching the width indicator move up or down the measurement scale on the left end of the Commander s frame Release the door width adjustment switch when the width indicator reaches the measurement of the width of your door with in Control Transformer The control tran...

Page 37: ...n Override In feed Limit The arrow button sends the hinge carriage to the right The In feed limit button overrides the limit switch to return to a hinge pocket and machine it again 1 Normally the Start button on the auxiliary panel sends the carriage to the left then if the hinge router has been selected the next press on the start button will send it to the right machining as it goes 2 If the rou...

Page 38: ...ly unclamps and exits the door Auto In Out Door Only Automatically machines the door and out feeds the door Door Jamb Automatically machines the door and jamb 1 second after jamb is clamped Feed Option Jog FWD Manually controls the feed belts shifting toward the out feed end of the machine Jog REV Manually controls the feed belts shifting toward the in feed end of the machine StartSequence FRONT B...

Page 39: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 30 ...

Page 40: ...riate collar on the shaft below the hinge router Slide it so that its left edge indicates the measurement on the tape Notice that there s two center shaft supports just in case your collar location overlaps Be sure to set the collars so that the tightening screws are horizontal or the screw heads set the ferrous proximity sensors on the router carriage Tighten the collars firmly Instead of moving ...

Page 41: ...rough the stile In this case all backset pins are 5 16 longer and no pin is used to cut through the bottom skin Hinge Backset Jamb Space stop pins limit the cutter travel up into the jamb Notice that this pin contacts a bolt mounted to the chip out assembly The chipout block is spring loaded up to the contact the jamb edge during the jamb routing sequence The cutter is indexed off the edge of the ...

Page 42: ...tiple passes with a bit First turn off the machine and the routers and slide the hinge router air valve off Remove the pin that limits upwards router travel into the jamb and bolt the new chipout block in place you will need to hold the router up manually so the bit clears the new block Make sure that you have the proper pins selected for the hinge length Horizontal Travel and that the router sett...

Page 43: ... Three positions are standard the fourth position is back from the 3 hinge rout When both the special back positions are selected you will get a 4 hinge rout with the same centers as the 3 pocket All the settings for opposite swing doors will be the same as interiors since the pockets have not shifted towards the right You should color code the new turret bolts for reference Also when cutting 4 bu...

Page 44: ...dy weight This is different from operator to operator To adjust the torque limiters do the following 1 Remove the plate that is covering the sprocket and torque limiter 2 Once removed loosen the two set screws on the nut this will allow you to make your adjustments accordingly 3 Once you have adjusted the torque limiter to its appropriate setting tighten the set screws down so that the bolt does n...

Page 45: ...d H Blocks Cutter Radius 3 16 1 4 5 16 3 8 1 4 1 2 9 16 5 8 11 16 5 8 7 8 15 16 1 1 1 16 Jamb Backset Top Pin Cutter Radius 1 1 8 Pocket 1 3 8 Pocket 1 5 8 Pocket 1 4 2 1 3 4 1 1 2 5 8 2 3 8 2 1 8 1 7 8 3 Degree Special Set Up Information When cutting at 3 degrees you must subtract 1 32 from the Jamb Pocket Top Pin AND Door Hinge Backset Bottom Pine From zero degrees to 3 degrees your overall pock...

Page 46: ...rets on longest bolt position Put Jamb pin in 2 5 16 Adjust router tilt in height down 3 8 Adjust 1 4 shim on top of plate for chipout tilt in clearance Remove 5 32 pins for jamb height Turn on slide valve CommanderExteriorDoorRevealAdjustment The chipout block on the router carriage serves two functions 1 to reference off the jamb 2 reference off the door When changing either the reveal measureme...

Page 47: ...e the chipout adjusting shims at the top of the routing carriage as necessary 4 Loosen the handle at the base of the routing carriage below orange pancake cylinders 5 Turn the round knob just above the handle you have just loosened to adjust the stroke of the cylinders Cylinder Centerline Adjustment Knob 6 Re tighten the handle above the cylinder centerline adjustment knob 7 Turn on electrical pow...

Page 48: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 39 ...

Page 49: ...ti Stop for Locks Section OPTIONAL This system uses a pickle fork attached to an air cylinder to position the lock section A 1 shaft is mounted behind the indicator tape parallel to the bearings shafts Clamp collars to the shaft at common lock locations On top of the indicator tape little clamp on indicator arrows can locate positions corresponding to the collars To move the lock section flip both...

Page 50: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 42 ...

Page 51: ...he lock bore drill HIT THE EMERGENCY STOP IMMEDIATELY Check lock bore set up or the drill bit alignment with the chipout block and the aluminum chip out block housing could end up being machined along with your door LOCK BORE BACKSET CAUTION Change chipout location and face bore AT THE SAME TIME Turn OFF the AIR AND ELECTRICAL services Tag and Lock out the machine Failure to follow these instructi...

Page 52: ...e shank of a smaller diameter bit Care must be taken that 2 1 8 be maintained between the tip of the ring cutter teeth and the teeth on the main cutter or door face tear out will result You may need to adjust the bit s depth position in the collet TO ADJUST 1 Slide the bit in or out and relocate the collar so you will have a reference for the next time you use this set up 2 Adjust the limit switch...

Page 53: ...ither a square edge or a three degree beveled edge The bolts are color coded Red 1 Square Edge Blue 1 1 8 Square Edge Silver 1 Beveled Edge White 1 1 8 Beveled Edge Notice that no changes need to be made to these turrets in order to change among doors of varying thicknesses since the lock section centers the door when it clamps If for some reason the face plate is not centered on the latch hole yo...

Page 54: ...tchet handle Repeat this process on the other end of the lock section If you have any problems with inconsistent plate depth be sure that both bevel locks are mating correctly with the upper router carriage shaft Stop nuts attached to the upper 4 prong knobs make adjustments straight forward SIDE DRILL LATCH HOLE The side drill bit has a 4 long fluted section For 5 back sets and over bored dead bo...

Page 55: ... physical obstructions interfering with proper movement of the assemblies Once the back section is running smoothly replace the two drill bits in to the respective collets turn on and push in the plate router using the Acuflex wrench Fine a cull door you can ruin and make a practice cut following the next few steps After the bits have been installed you are ready to put a new chip out in by removi...

Page 56: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 48 ...

Page 57: ...r a misadjusted limit switch is more than likely the cause Depending on the model of limit switch you receive 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 If the arm is moved to the full extents of its travel and you do not here the limit switch Click the switch needs to be adjusted here is how you adju...

Page 58: ...o is broken by either a door a moving part on the machine such as the thru beams these beams may either stop operation or initiate operation depending on their location and function The sending and receiving units are in one unit these operate in the same manner as the ones described previously Note When a machine stops for no reason it is usually the fault of dirt photo eye or a misaligned limit ...

Page 59: ...ly operated by pushing the slotted button on the end of the valve If you wish to keep the valve open the push button assembly can be removed using and open ended wrench and inserting a 3 8 N C cap screw DO NOT over tight when reassembling the valve 5 If the valve seems to be leaking the seals may be dry or contaminated with water or it maybe that the cylinder O rings are damaged and air is passing...

Page 60: ...sh each of the buttons one at a time When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty Adjusting the flow controls to change the cylinder extension speed is done by the following drawing Please review this drawing as this adjustment is not done in a normal manner To change cylinder extension speed To change cylinder retr...

Page 61: ...ghted 120V control power terminal strips This will indicate power supply from the respective circuits Idec controllers also have lights on them for the input and output functions You can easily find out which circuits are failing by watching the lights turn on or off Compare the lights on the IDEC controller to the electrical diagram to determine what systems are being affected IF THE POWER STOPS ...

Page 62: ...you that there are no overloads or emergency stops tripped On computer controlled units make sure that the POWER and RUN lights are lit at the lower left of the computer 4 Most electrical problems are related to mechanical malfunction i e stuck motors jammed chain non tripped limit switches etc The most common failure is an improperly adjusted limit switch To check a limit switch manually operate ...

Page 63: ...front or both Check to ensure that this switch is properly selected THE SIX SHOOTER IS NOT MOVED FULLY TO THE RIGHT 1 The front section will not operate if the Six Shooter has not been rolled all the way to the right at its home position and makes contact with the limit switch located at the upper right corner of the Six Shooter track frame THE THROUGH BEAM LENSES ARE DIRTY 1 In order for any of t...

Page 64: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 56 ...

Page 65: ... free travel of the carriage Check that the air pressure is at operating specifications and adjust as necessary Check the air cylinder to see if the seals are bad 2 One of the router cords maybe dangling in front of a photo eye or its line of sight Check to ensure that all router cords are properly tied out of the way GUARDS ARE MISS ALIGNED 1 Check that each of the guards is squarely positioned o...

Page 66: ...ROUGH BEAMS ARE BAD 1 When the front section is down and out of the way the through beams should light up to indicate that they are operating If they don t light up replace ENVIRONMENT TOO COLD 1 The lubrication required for smooth movement of all assemblies must be sufficiently warm to afford any of its viscous qualities If it is very cold in your shop it will prevent smooth movement of the front...

Page 67: ...ound the perimeter of the hinge and face plate pocket usually is a good indication that your router bit is dull and needs to be replaced It might also indicate that the speed in which the router is moving within the pocket is to fast RING AROUND THE POCKET This is an indication that the arbor is running out or the arbor is not tight in the router collet Another tip is to check the router bit and s...

Page 68: ...or face tear out will result Turning the selector switch to REG allows the smaller bit to drill through the door but not so deep that the counter bore touches the door Deep sends the counter bore all the way through the door until it just etches a groove in the chip out block It is important when switching from 1 3 8 doors to 1 3 4 thick doors that you use the proper shims to make the difference u...

Page 69: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 62 ...

Page 70: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 64 ...

Page 71: ...This page contains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 64 ...

Page 72: ...tains Kval Inc proprietary information and is not to be duplicated or disclosed to unauthorized persons 67 Our Mission Innovation Quality and Honesty Kval Inc 825 Petaluma Blvd So Phone 707 762 7367 Fax 707 762 0485 ...

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