Kval Commander III Operation Manual
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Kval Commander III Operation Manual

Door system with kvalcam
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Operation Manual
Published: October 6, 2020
Innovation, Quality & Honesty
Commander III Door System
With KvalCAM

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  • Page 1 Operation Manual Published: October 6, 2020 Innovation, Quality & Honesty Commander III Door System With KvalCAM...
  • Page 2 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.
  • Page 3 KVAL Commander III Operation Manual Your Feedback is Welcome: To help us design products that make your job easier and your business more successful, we'd like to gain your perspective about your user experience with our product - that is, the manual, the machinery, the software, etc.
  • Page 4 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”.

  • Page 5: Table Of Contents

    Table of Contents Introduction to the Commander III Chapter 1 Chapter 1 at a Glance.............. 1-1 Overview of the Commander III System ........1-2 Table of Options...................1-3 About this Manual .................1-5 Safety Sheet Sign-Off Sheet..............1-5 Safety First!................1-6 Safety Sheet Sign-Off Sheet..............1-6 Safety Terminology of Labels..............1-6...
  • Page 6 About the Validation Screen ...............2-35 Outline ....................2-36 About the LiteCutout Feature Detail (DL-NCD Only) ....2-37 Process....................2-37 About the LiteCutout Screen...............2-41 About the Work Area Coordinates ............2-42 Sample Oval Cut.................2-43 Common Terms ............... 2-45 Door Job .....................2-45 Door Data ...................2-45 KVAL Commander III Manual...
  • Page 7 Load Door Job from KvalCAM ..............3-3 Load Door .....................3-4 Set-Up Front Section and Machine the Door........3-5 Powering Operations for the Commander III ......3-6 How to Power Up the Commander III ...........3-6 Home the Commander III ..............3-7 How to Power Down the Commander III ..........3-7 Emergency Shutdown and Recovery ...........3-8...
  • Page 8 About the Tool Path Preview Test Screen........ 3-32 About the Status Screen ............3-33 About the Log Screen .............. 3-34 Description of the Six Light Panel ........... 3-35 Calibration of Commander III Chapter 4 Chapter 4 at a Glance.............. 4-1 About Calibration ..............4-2 About the Calibration Menus and the Calibration Reference Cut ..4-2...
  • Page 9 Hinge Head (Over All).................4-12 Hinge Tools ..................4-13 Chisels Calibration................4-14 Hinge Carriage Location ..............4-15 Lock Head...................4-16 Opt FC: Commander III Faceplate and Chisel Calibrations....4-18 Lock Head General................4-18 Axis Calibration Direction..............4-19 Plate Router Calibration (Back Section) ..........4-19 Chisel Calibration (Back Section) ............4-20 Door Stops ..................4-20...
  • Page 10 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 KVAL Commander III Manual...

  • Page 11: Introduction To The Commander Iii

    CHAPTER 1 Introduction to the Commander III This chapter provides an overview of the KVAL Commander III System and important safety information to follow when operating the machine. Chapter 1 at a Glance The following information is available in this chapter...

  • Page 12: Overview Of The Commander Iii System

    • Door hand indicator light to speed processing in a companion 700C door framer. Operators Interface: The operator interface for the Commander III is simple and requires very minimal training to cre- ate door specifications. Dimensions are entered at the amply sized 19” Beckhoff touch screen for hinge layout from the door top, hinge reveal, hinge size, ¼”radius, 5/8”radis or square corners,...

  • Page 13: Table Of Options

    Beckhoff 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 mon- itor all machine functions from our offices in Petaluma when required.
  • Page 14 Overview of the Commander III System Option Title Description Option Best 93K (Cylindrical) Gearbox See Above (Option W) with Air motor Option Schlage “D” Serial #792 Drill See Above (Option W) Gearbox with Air motor Option Yale 80-7150-0047-010 Drill See Above (Option W)

  • Page 15: About This Manual

    Overview of the Commander III System About this Manual This manual is part of a package delivered with the machine line. Integration Package includes the following: includes the following: Operation Manual Chapter Title Description Introduction Descriptions of Machine Line and Safety Information.

  • Page 16: Safety First

    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 pro- vide safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.
  • Page 17 Before performing any mainte- nance or repairs on this machine turn off the main air disconnect. Lockout and tagout this connection. See “Lockout Tagout Procedure” on page 1-10. KVAL Commander III Operation Manual...
  • Page 18 This should be done in accordance with applicable state and/ or federal code requirements. KVAL Commander III Operation Manual...
  • Page 19 Safety First! Compliance with Codes and Regulations 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.

  • Page 20: Lockout Tagout Procedure

    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. KVAL Commander III Operation Manual 1-10...
  • Page 21 • If more than one person is working on the machine, then each additional person places a lock and tag on each disconnect. • Only each operator may remove their own lock and tag. KVAL Commander III Operation Manual 1-11...

  • Page 22: Follow The P-R-O-P-E-R Lockout Rule Of Thumb

    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 KVAL Commander III Operation Manual 1-12...

  • Page 23: Zero-Energy To Start-Up

    Replace Guards Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the KVAL Service team. See “Getting Help from KVAL” on page 1-15. Check Controls Confirm that all switches are in the “OFF”...
  • Page 24 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. KVAL Commander III Operation Manual 1-14...

  • Page 25: Getting Help From Kval

    • 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 AM to 1:30 PM Pacific Standard Time, Friday KVAL Commander III Operation Manual 1-15...

  • Page 26: On-Line Help

    Product Return Procedure If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure below to return the machine or part. Note: Non-Warranty returns are subject to a 15% restocking charge.

  • Page 27: How To Download The Service Application

    Download Application To download the application, go the KVAL website ( http:// www.kvalinc.com At the KVAL website, select the tab. Follow the instruc- Support tions on the Support web page. Click the Download button to download the application that...
  • Page 28 Session code: An internal number to track this machine. It is auto filled. Your Name Field: Enter your name. The KVAL techni- cian will use this field to identify this machine. Description: Enter machine Serial number and issue.
  • Page 29 How to Download the Service Application Page Intentionally Left Blank KVAL Commander III Operation Manual 1-19...

  • Page 30: Safety Sign-Off Sheet

    Name (print):__________________Signature: __________________ Date:____/____/___ Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the KVAL website ( http://www.kvalinc.com You may also contact our Service Department at (800) 553-5825 or email at service@kvalinc.com.
  • Page 31 Examples of Features in the Job Preview Window. page 2-31 Job Preview Examples Example of Validation issues. page 2-34 About Validation Information about using the LiteCutout Feature. page 2-37 About LiteCutout Feature Descriptions of terms used in KvalCAM. page 2-45 Common Terms KVAL Manual...
  • Page 32 A KvalCAM Door Job . The communicates with the Machine or Machine Line to process the Data Features Door Job door. The figure below illustrates the multiple inputs that can be used by to create a door. KvalCAM KVAL Manual...

  • Page 33: Summary Of The Kvalcam Interface

    The Libraries include three tabs, the , the and the Door Job Library Feature Group Library Door . At each library screen, files can be created, edited, cloned, deleted, and downloaded. Data Library Each Library contains a version section. KVAL Manual...

  • Page 34: Machine Control

    Each machine has a distinct control screen. is purpose-built to allow all compatible KvalCAM 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 KVAL Manual...

  • Page 35: About The Libraries

    Door Data Library • The Feature Group Library Detail Door Job Door Data Feature Group Saves Cut Information Saves Door Parameters Many Number of Feature Groups Allowed Load Work Onto Machines (Cut Doors) 1. For Testing Purposes Only KVAL Manual...

  • Page 36: Around The Door Job Library 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 attached to the many files. Door Job • Files support revisions. KVAL Manual...

  • Page 37: Around The Feature Group Library 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 files Door Job • Files support revisions. • Tracks variants. KVAL Manual...

  • Page 38: Controls At The Library Screen

    Note: The operations described here are common to all screens. Note: The is hidden. Select the line to the right and drag to the Revision Display Panel left to display this pane. Library Screen FIGURE 2- 1. KVAL Manual...

  • Page 39: Using The Door File Table

    , located in the upper right hand corner. Display Deleted Check Box Deleted files are highlighted in red. Select the file to be recovered. At the bottom of the page, select the to recover the file. Restore Button KVAL Manual...

  • Page 40: Using The File Control Buttons

    To Clone a File Select the file to be cloned from the table. Select the Clone Button. At the pop-up window, rename the file and, if needed, update the description. Select the to complete the process. Save Button KVAL Manual 2-10...

  • Page 41: Using The Delete/Restore Button

    Select the file to be deleted from the table Select the Delete Button At the pop-up window select to delete the file. Note: To restore a file, see “Using the Display Deleted Check Box (Recover a Door File)” on page 2-9. KVAL Manual 2-11...

  • Page 42: Using The Diff Button

    Use the Diff Button to Compare Two Files. Select 2 files to compare. Select the Diff Button 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. KVAL Manual 2-12...

  • Page 43: About The Database Icon

    If not connected, verify path) Tip: • Server (Multiple servers may be created) • Database (This is the name assigned to the database) • User (Assigned User) • Server version (OEM server version) • Database (Kval database version) KVAL Manual 2-13...

  • Page 44: About Revisions

    The selected file will be highlighted in green and will be assigned as the principle file. Revisions at the Door Job Library file revisions be compared and any file can be assigned as the principle. Door Job KVAL Manual 2-14...

  • Page 45: Revisions At The Door Data Library

    Door Feature file as the principle. The lower panel displays: • The that contain the selected Door Jobs Feature Group File. • The Revision ID • Any Variant in the files.(For a Variant definition, see “Variant” on page 2-48. KVAL Manual 2-15...
  • Page 46 About Revisions KVAL Manual 2-16...

  • Page 47: About Door Job Creation

    Create , select the item from the table, bottom of the screen. then select the button Edit /View on the bottom of the page. bottom of the screen. Screen Shot of Job Creation FIGURE 2- 2. KVAL Manual 2-17...

  • Page 48: About The Job Name Menu

    Door Core: Clamping pressure will adjust to the selection. (Unspecified, Hollow, or Foam) FeedRate% Override: Adjust the plunge rate of the drill / routers. Adjusts to door materials. For example, for a harder material would call for a lower percentage. KVAL Manual 2-18...

  • Page 49: About The Feature Tree Menu

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

  • Page 50: About The Feature Tree Menu

    Validation Report • : Select a Group or Child. Right click the mouse button. Cut/Copy and Paste Choose Cut or Copy from the list. Position mouse at the desired location in the tree. Right click and choose Paste. KVAL Manual 2-20...

  • Page 51: About The Selected Feature Details Menu

    Door Job. Select Add Property. Add a Name and Expression. Error checking will help in adding the correct data. In the Children Feature Detail Screen, add a hashtag (#) in front of the created property name. KVAL Manual 2-21...

  • Page 52: About The Selected Feature Details Menu (Child Level)

    • Lock Edge • Hinge Jamb • Lock Jamb Data Table: Parameters of the cut. Includes Hinge Predrill locations. Manage Augmentations: Add augmentations to the created Feature. Augmentations are created at the factory to ad to common cuts. KVAL Manual 2-22...

  • Page 53: About The Control Buttons

    Select the Export to DXF Button to create a blueprint of the Door Job. The background program will translate the parameters to a dxf file. To view the file use a program that opens.dxf files. (For example: Auto-Cad ® Draftsight ® ) Use this blueprint to share for review. KVAL Manual 2-23...

  • Page 54: About The Job Preview Screen (2D And 3D)

    • Top End view or and OFF Line or and OFF view. Note: May • Hinge Edge use the mouse • Lock Edge wheel to zoom in • Hinge Pivot Face and out. • Opposite Pivot Face KVAL Manual 2-24...
  • Page 55 Select the 3 D Tab to display a three dimensional view of the . Right click the mouse to Door Job control the movement of the 3 D display. are color coded and listed on the display. Preview Surfaces KVAL Manual 2-25...

  • Page 56: About The Machine Line Screen

    For each machine, a table shows job name, quantity of remain- ing doors, doors being processed, and status of the machine. Queued Jobs: Shows a list of the upcoming jobs. Line Controls: Common operations to control the machine line Machine Line Screen KVAL Manual 2-26...
  • Page 57 Door Job doors left in the Door Job: Lists the name of the Job being processed. The Job name reflects the name assigned in the Door Job Library. Machine: Lists the machines in the line. KVAL Manual 2-27...
  • Page 58 Creation Time: List the time when the job is put in queue. Template: List the File name of the Template. Job: List the file name of the Job. Queue Order: Lists the jobs that are going to be processed KVAL Manual 2-28...
  • Page 59 Operator’s Screen Reset the Machine Line: Press to Home the Machine Line: Press to reset the every machine in the Home every machine in the line line. You Must Home the line after this reset is performed. KVAL Manual 2-29...

  • Page 60: About Backing Up Data And Checking The Revision Status

    About Backing up Data and Checking the Revision Status Right Click the KVAL Icon at the bottom of the screen to display this popup. Note: Select icon from the windows screen and drag to the favorites bar for access to this icon.

  • Page 61: Job Preview Examples

    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 KVAL Manual 2-31...

  • Page 62: Door Edge (Lock Preview)

    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 KVAL Manual 2-32...

  • Page 63: Door Edge (Hinge Preview)

    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 KVAL Manual 2-33...

  • Page 64: About Validation

    Door Job. An Orange Box will highlight the group with an error. In this sample, the has an error Lock Edge Child To investigate the error, select the Vali- button at the bottom of dation Report the display. KVAL Manual 2-34...

  • Page 65: About The Validation Screen

    About Validation 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 KVAL Manual 2-35...

  • Page 66: Outline

    Lock Edge routine Either change the depth in the table of the Feature Table or select Commander 3-Tool Con- and change the fig- Lock Tools depth in the Depth Stop (Z Loca- field to match desired tion) depth. KVAL Manual 2-36...

  • Page 67: About The Litecutout Feature Detail (Dl-Ncd Only)

    To add a new LiteCutout If needed, add a Feature Group. Add a to the Child Feature Tree Select from the drop down menu and add a LiteCutout Feature Type Feature .add a Feature Name. Name Select the Edit Button. KVAL Manual 2-37...
  • Page 68 About the LiteCutout Feature Detail (DL-NCD Only) Add Group Add Child Select LiteCutout and Name Select the Edit Button working space is displayed. LiteCutout Select the and select the desired file from your directory. If Import DXF Button needed, manipulate the shape. KVAL Manual 2-38...
  • Page 69 About the LiteCutout Feature Detail (DL-NCD Only) Import DXF file In this example, an oval DXF file was imported. Add the file into by selecting the KvalCAM OK Button. Input to put the cut onto the door. WLocation LLocation KVAL Manual 2-39...
  • Page 70 About the LiteCutout Feature Detail (DL-NCD Only) If finished with editing the , run the door. Door Job KVAL Manual 2-40...

  • Page 71: About The Litecutout Screen

    About the LiteCutout Feature Detail (DL-NCD Only) About the LiteCutout Screen This section describes selections on the Screen. LiteCutout KVAL Manual 2-41...

  • Page 72: About The Work Area Coordinates

    0,0 origin point: Referenced to the LLocation and WLo- cation on the door. X Negative: X Positive: goes toward goes toward the the Top of the Door. Bottom of the Door Y Negative: goes toward the Lock Edge. KVAL Manual 2-42...

  • Page 73: Sample Oval Cut

    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. KVAL Manual 2-43...
  • Page 74 DXF file. The Shape 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 any selected point on the shape. KVAL Manual 2-44...

  • Page 75: Common Terms

    Figure 2- 5 on page 2-46 shows an KvalCAM Door Job example of the information in Door Data More information about can be found at “About the Door Data Menu” on page 2-18. Door Data KVAL Manual 2-45...

  • Page 76: Feature Group

    Figure 2- 4 below shows a collection of Feature Features Door Job Groups in a Door Job. More information about can be found at “About the Feature Tree Menu” on Feature Groups page 2-19. Feature Group Panel FIGURE 2- 6. KVAL Manual 2-46...

  • Page 77: Feature

    Door Data Feature Group Ad Hoc Door Job with any in the library. allows for a to be created or edited Revision KvalCAM Ad Hoc Door Job independent of and/or in the library. Feature Groups Door Data KvalCAM KVAL Manual 2-47...

  • Page 78: Variant

    Figure 2- 8 Shows an example of a Door Lite Cutout with a variant that is associ- Feature Group ated with a Test Door Job. Example of a Variant FIGURE 2- 8. KVAL Manual 2-48...

  • Page 79: Diff

    Door Preview Screen Figure 2- 9 below shows the axis icons. Note the icon relationship to the door graphic. Represents the Length axis Represents the Width Axis Represents the Thickness Axis Axis Icons in Job Preview FIGURE 2- 9. KVAL Manual 2-49...

  • Page 80: Validation

    Some cuts in fringe cases may pass validation that result in non-conforming cuts (cut does not match visual representation). Figure 2- 11 shows an example of a Variant Report. Follow the Fail tags and Descriptions to solve error. KVAL Manual 2-50...
  • Page 81 Common Terms Example of a Validation Report FIGURE 2- 11. KVAL Manual 2-51...

  • Page 82: Operation Of The Commander Iii

    Chapter 3 at a Glance The following information is available in this chapter Section Name Summary Page A summary of the Commander iii machining pro- page 3-2 About the cess Commander III Process A summary of the steps to machine a door.

  • Page 83: About The Commander Iii Process

    About the Commander III Process About the Commander III Process Summary of the door process. Download door job Feed the door into machine Go to main screen Make machine adjustments to the displayed values on the main screen if necessary.

  • Page 84: Summary Of Machining A Door

    Libraries Manual included in this manual set. Start the Process Ensure factory air is present at the machine and the Commander 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.

  • Page 85: Load Door

    Feeder or table to the Door Stop Ensure Door is set and clamped in machine. Place Jamb on the jamb shelf butted against the stop Press Jamb Clamp foot pedal to clamp the jamb Jamb Stop Door Clamps Jamb Clamps Commander III Operation Manual...

  • Page 86: Set-Up Front Section And Machine The Door

    If all groups are finished and the Button is active, the door will Door Finished feed out If needed, move the highlighted the H-Block. After all groups are completed, the door will feed out of the machine Commander III Operation Manual...

  • Page 87: Powering Operations For The Commander Iii

    Powering Operations for the Commander III Powering Operations for the Commander III This section describes how to power up and to power down the Commander III. Powering up the system includes: • Applying power to the entire system • Starting the Control Circuit Powering down the system includes: •...

  • Page 88: Home The Commander Iii

    Commander III measures its movement and cutting process. If power is lost or the Commander III is re-set, the homing routine must be performed again to reset the zero reference. Press the button on the touch screen.

  • Page 89: Emergency Shutdown And Recovery

    Powering Operations for the Commander III Emergency Shutdown and Recovery There are emergency shutdown (E-Stop) switches located at key points around the machine. Note: Depending on options of the machine, the E-Stop buttons may be located at various locations. The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.

  • Page 90: About Machine Status Feedback

    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. Commander III Operation Manual...

  • Page 91: About The Commander Iii Interface Screens

    About the Commander III interface Screens About the Commander III interface Screens Door Jobs created in are processed at the interface screens. For information about KvalCAM Kval- See “About KvalCAM” on page 2-1. Operator Screens contains the controls to operate the machine.

  • Page 92: About The Main Control Screen

    The illustration below, displays a screen without a door loaded from the menu. Door Job Machine Controls Machine Feedback and Machine Controls (See page 3-12) (See page 3-17) Commander III Main Screen FIGURE 3-1. Commander III Operation Manual 3-11...

  • Page 93: Machine Controls Section

    Control the Feed in of the door Carriage Shift Shift the Carriage into pocket and out of pocket. Ball Catch Enable or disable the ball catch function Speed Control Control the percentage of machine speed Commander III Operation Manual 3-12...

  • Page 94: About The Main Control Section

    Use this mode to check the machine operation without making a cut on the door. With the setup mode set to on, the button will change to an orange back- ground. In the mode the machine is in normal operation. Commander III Operation Manual 3-13...

  • Page 95: About Sequence Control Section

    • Press and hold the button to close the Close: Close width adjust carriage. To stop the carriage, release the button. The carriage will also stop if the nega- tive travel limit eye is activated. Commander III Operation Manual 3-14...

  • Page 96: About Carriage Control

    Carriage Shift Button carriage into the machine or away from the machine. Move the carriage out to improve access to the front of the machine and to the tools of the carriage. Commander III Operation Manual 3-15...

  • Page 97: About Ball Catch

    Select to enable or disable if desired. About Speed Control Adjust the speed of the cut. Press the graduated speeds or select box or enter a desired speed. The speed can be changed during real time processing. Commander III Operation Manual 3-16...

  • Page 98: Machine Feedback And Machine Controls

    A display of the sequence of the door machining. Hinge Task Control Information A display of hinge information Shelf Pin and Jamb Stop Jamb Stop (LH) location and Shelf Pin selection. Lock Task Information a display of back section processes Commander III Operation Manual 3-17...

  • Page 99: About The Top Feedback Bar

    Displays the routine, process step in the door job. About Hinge Tasks Control In this section the settings are displayed. View the H-Block setting derived from the Door H-Block Job. Adjust the H-Blocks to the settings. Commander III Operation Manual 3-18...

  • Page 100: Hinge Block Descriptives

    H-Block not Used: Using H-Block not Sensed: Displayed the Door Job information, only if previous location of data is this H-Block is not used in not saved or any door job has not the machining procedure. been run. Commander III Operation Manual 3-19...

  • Page 101: Shelf Pin Configure And Jamb Stop Section

    Note: Shelf Pin calculations will revert to zero if machine is powered down. Note: Different size pins can be ordered through KVAL Sales and Service. Jamb Stop Move the Stop to the displayed value on the Left Hand Doors only: screen.
  • Page 102 • Lock Backset: Feed back only. the length of the backset on the lock • Edge Plate: Select to enable or disable the edge plate routine • Edge Bore: Select to enable or disable the edge bore. Commander III Operation Manual 3-21...

  • Page 103: About The Manual Servo Control Screen

    From this screen, you can control certain functions manually. This function is ordinarily used in troubleshooting, checking cut specifications, and maintenance. Measurement (Enable/Disable): Auto Feed (Enable /Disable): Press to toggle the operation of Press to toggle the auto feed of the thickness probe (encoder). door ON or OFF. Commander III Operation Manual 3-22...

  • Page 104: Manual Servo Control

    Outfeed Stop 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. Commander III Operation Manual 3-23...

  • Page 105: Hinge Carriage

    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. Commander III Operation Manual 3-24...

  • Page 106: About The Tool Config Tabs

    • 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. List of Tools Available Pop-Up Menus: enter tool data.(Router,Drill and Chisels (opt) Commander III Operation Manual 3-25...

  • Page 107: Unlock The Tool Slot Configuration

    Identify the tool that needs replacement.Measure the dimensions and capture the data. (Use this information to populate the pop- Drill or Router up screens). Select the Tool Slot Enter the data into the pop-up screen. Commander III Operation Manual 3-26...

  • Page 108: Enable Or Disable Tool

    • The tool slot menu will turn red. • The tool will not operate during the cutting process To Enable • Re-select the Enabled Check-Box About Hinge Tool Configuration Locations of the Tools are shown in the figure below. Commander III Operation Manual 3-27...

  • Page 109: About Lock Tool Configuration

    Door Job Note: Select the to store any changes made to the parameters. Save Button Select Save to the store any changes in the parameters. Select to burn in a new Chipout Block Commander III Operation Manual 3-28...
  • Page 110 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 Depth Length Commander III Operation Manual 3-29...
  • Page 111 See “Option W: Lever Lock Drill (Function Drill)” on page 5-16 more information. Face Bore Disable or enable the Face Bore. Settings for two cuts. Diameter, Depth limit, and Backset location of Lock Bore, Depth Diameter Backset Commander III Operation Manual 3-30...

  • Page 112: About The Ball Catch Configuration

    Offset is referenced from the top edge of the door. OffSet (Top Edge Reference) Movable Stop: Reference from the door edge to the center of the Ball Catch Hole Depth Backset: Edge of door to the Center of the Hole Commander III Operation Manual 3-31...

  • Page 113: About The Tool Path Preview Test Screen

    Center Circle represents the tool Point and the animation rep- resents the path Select a G-Code routine form the drop down menu. Select the Render Button View the path of the tool on the screen. Commander III Operation Manual 3-32...

  • Page 114: About The Status Screen

    (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. Filter Data List of Parameter of Door in Process Status is listed by Location Status Screen FIGURE 3-2. Commander III Operation Manual 3-33...

  • Page 115: About The Log Screen

    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.

  • Page 116: Calibration Of Commander Iii

    • Overview of the Setup Screens • Flow Chart of Calibration • Before you Calibrate This section describes the dimensions of the cali- page 4-10 About the Calibration bration slot. Routine KVAL Commander III Operation Manual...

  • Page 117: 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.

  • Page 118: Flow Chart Of Calibration

    About Calibration Flow Chart of Calibration The flow chart below illustrates the steps in performing a calibration on the Commander III. Calibration Process Flowchart FIGURE 4- 4. KVAL Commander III Operation Manual...

  • Page 119: About The Calibration Tabs

    Finding errors from these 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.

  • Page 120: Unlock The Calibration (Option)

    Access to the calibration is password protected. (Optional) Select the button Unlock At the pop-up, enter Password the password and select OK to continue. The calibration message will change from a red ''Calibration is Locked '' to a green Calibration is Unlocked”. KVAL Commander III Operation Manual...

  • Page 121: How To Enter Calibration Data

    Note: Maximum offset is 0.50 inches. If more than 0.50 inches of adjustment is needed, there is a high probability that another issue may be causing a problem. If issues can not be resolved, contact the KVAL Service Center KVAL Inc. (1- 800-553-5825).

  • Page 122: About Restore Points

    ‘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 In-Feed Y Axis Positive movement Z Axis Positive movement X Axis Positive movement Left Hand Rule Front Section FIGURE 4-6. KVAL Commander III Operation Manual...

  • Page 123: Axis Direction For Back Section

    Point at the Back Section from the rear of the machine at the cut of the door. In-Feed Y Axis Positive movement Z Axis Positive movement X Axis Positive movement Left Hand Rule Back Section FIGURE 4-7. KVAL Commander III Operation Manual...

  • Page 124: Suggested Order Of Calibration

    Repeat steps 2 through 3 above until all parameter are in specification. When satisfied with the left hand calibrations, Machine a right hand door to verify that all calibrations are set. KVAL Commander III Operation Manual...

  • Page 125: About The Calibration Screens

    Calibrate the X axis location of the in-feed and out feed stops “Door Stops” on page 4-20 Fast Lock Timing Adjust the time of deployment lock router. see “Fast and Slow Lock Plate Timing” on page 4-21 KVAL Commander III Operation Manual 4-10...

  • Page 126: Opt Fc Added Calibrations

    Adjust the depth of Jamb locations for a batch of untrue doors “Door and Jamb Depth Adjustment Mapping” on page 4-24 Opt FC Added Calibrations Option FC adds corner squaring and full CNC control of face plate routing. Commander III machines with this option have calibrations. Follow the process order in “Suggested Order...

  • 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. ‘ KVAL Commander III Operation Manual 4-12...

  • Page 128: Hinge Tools

    Chisel corner off center, overlapping cut pocket, drill holes off center. For example: Note: First verify that the is calibrated before performing any of Hinge Head (Over All) these routines. Select the tool to calibrate inde- pendently of the carriage KVAL Commander III Operation Manual 4-13...

  • Page 129: Chisels Calibration

    Upper Left Chisel Chisel Jamb Door Lower Left Lower Right Chisel Chisel Adjusting the Chisels Identify the corner or comers to be calibrated. a.Upper Left Chisel b.Upper Right Chisel c.Lower Left Chisel d.Lower Right Chisel. KVAL Commander III Operation Manual 4-14...

  • Page 130: Hinge Carriage Location

    ” button to combine the two numbers to create reference. Combine 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. KVAL Commander III Operation Manual 4-15...

  • Page 131: Lock Head

    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. KVAL Commander III Operation Manual 4-16...
  • Page 132 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. (Option: Thickness encoder calibra- tion is also located in this section) KVAL Commander III Operation Manual 4-17...

  • Page 133: Opt Fc: Commander Iii Faceplate And Chisel Calibrations

    About the Calibration Screens Opt FC: Commander III Faceplate and Chisel Calibrations Option FC adds corner squaring and CNC control of face plate routing. Commander III machines with this option have calibrations. added Note: Before performing these calibrations, it is suggested to follow the order in “Suggested Order of Calibration”...

  • Page 134: Axis Calibration Direction

    Note the Positive # Negative # measurement value. Run Calibration until specification is met. Z: Positive number Positive moves tools in, negative Number number moves tools out Negative Positive Negative Number Number Number KVAL Commander III Operation Manual 4-19...

  • Page 135: Chisel Calibration (Back Section)

    Number Number Number 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. KVAL Commander III Operation Manual 4-20...

  • Page 136: Fast And Slow Lock Plate Timing

    The router time can be adjusted to match the flow control that is mounted on Slow Plate Routine 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. KVAL Commander III Operation Manual 4-21...

  • Page 137: About Lock Plate Timing Calibration

    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 until the Stop tim- ing with the door is in synchronization. KVAL Commander III Operation Manual 4-22...

  • Page 138: H-Block Display And Jamb Adjustments

    About the Calibration Screens 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. KVAL Commander III Operation Manual 4-23...

  • Page 139: Door And Jamb Depth Adjustment Mapping

    If it is too shallow, enter a positive number to adjust the routers. Machine another door and repeat until offset is corrected KVAL Commander III Operation Manual 4-24...
  • Page 140 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 ” Door and Jamb Adjustment FIGURE 4- 4. Fast Lock Plate Timing Menu FIGURE 4- 5. KVAL Commander III Operation Manual 4-25...

  • Page 141: Special Options (Calibrations)

    Measure a know good door. The door should be true and possible. Capture the . (This measurement is used to compare to the thickness Thickness Measurement captured by the feeler encoders.) KVAL Commander III Operation Manual 4-26...
  • Page 142 Enter the offsets from the averages and the measured door in the boxes under the Menus. Door Width Feelers Door Length Feelers Enter a negative offset to move the thickness adjust clamps closer. Enter a positive offset to move the thickness adjust clamps further apart. KVAL Commander III Operation Manual 4-27...

  • Page 143: Tour Of The Commander Iii

    CHAPTER 5 Tour of the Commander III This chapter describes components, assemblies of the Commander III Chapter 5 at a Glance The following information is available in this chapter Section Name Summary Page Descriptions of the operation of the parts and page 5-2 Operator’s Tour...
  • Page 144 Back Section See “Back Section:” on page 5-7. Ball Catch (X2) See “Option BC: Ball Catch” on page 5-18. Out Feed “Out-Feed:” on page 5-9. Identification of Key Assemblies of Commander III FIGURE 5- 8. KVAL Commander III Operation Manual...
  • Page 145 Adjusts to the width of the door Feed Motor: Drives the Door In-Feed System: Door Enters Machine through the here. Sensors triggered and width is machine. adjusted to door Key Assemblies on the In-Feed Section FIGURE 5- 9. KVAL Commander III Operation Manual...

  • Page 146: Front Section

    • Operator Station • Hinge Carriage • H Blocks • Door Stops • Jamb Stop • jamb Clamps Door Stops: Located at In-Feed and Out-Feed Operator Station Jamb Stop Hinge Carriage H Block Jamb Clamps KVAL Commander III Operation Manual...

  • Page 147: About The Operators Station

    Start or Stop Control Transformer Start Sequence Machine (Com- (Start cutting) (System ON or OFF) puter ON or OFF) E Stop(: Press to Stop all machine functions Operators Station with touch Screen Interface FIGURE 5- 10. KVAL Commander III Operation Manual...

  • Page 148: Hinge Carriage

    Router. The CR Router door routes in the opposite direction of the Standard Router. Provides a cleaner cut. Hinge Carriage Parts FIGURE 5- 11. KVAL Commander III Operation Manual...

  • Page 149: Back Section

    Lock Bore Motor and Drill: Face Plate Motor and Drill: Drills locks holes on the face Feed Belt: Routs face plate. of the door Feeds Door through Machine Key Assemblies on the Back Section FIGURE 5- 12. KVAL Commander III Operation Manual...

  • Page 150: Option Fc: Cnc Faceplate And Chisels

    Operator’s Tour Option FC: CNC Faceplate and Chisels Option FC adds corner squaring and CNC control of face plate routing. Commander III machines with this option have calibrations. added Z Axis Y Axis Servo Servo Motor Motor Back Section Valve Bank:...

  • Page 151: Out-Feed

    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 available Key Assemblies on the Out-Feed Section FIGURE 5- 13. KVAL Commander III Operation Manual...

  • Page 152: About The Electrical Panels

    High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off. If working on the panel, follow the safety protocol as described in Chapter 1. The Commander III has a Main Electrical Panel and a High Frequency Panel. The Main Electrical Panel: •...

  • Page 153: The High Frequency Panel

    • Pre Drill Router • Face Plate Router • Width Adjust Contactor and Thermal Overload Circuits Control Transformer • Bolt Drill Motor • Lock Bore Motor Overview of High Frequency Panel FIGURE 5- 15. KVAL Commander III Operation Manual 5-11...

  • Page 154: Description Of The Six Light Panel

    Description of the Six Light Panel 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: Control Power Overload Relay E-Stop...

  • Page 155: About Switches And Sensors

    24VDC and sends it to the PLC. • As a result, if a metal object is sensed, the output of the sensor equals 0VDC Sensors on Piston and Cylinder KVAL Commander III Operation Manual 5-13...
  • Page 156 • .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 KVAL Commander III Operation Manual 5-14...

  • Page 157: Options

    Note: The Lock functions is not available with this option. Standard Door Narrow Door Sensors: The Sensors width of the door is com- pared to the Standard Sen- sor inputs to activate. Narrow Door Fence Pneumatic Con- trols for Narrow Door KVAL Commander III Operation Manual 5-15...

  • Page 158: Option W: Lever Lock Drill (Function Drill)

    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 information about changing a drill assembly, see then Maintenance chapter of the Service Manual. Lever Lock (Function Drill) KVAL Commander III Operation Manual 5-16...

  • Page 159: Option: Thickness Feelers

    Thickness Feeler on the back section of the machine. Thickness Feeler Menu Additions Some added features to the interface for this option are located in the Calibration Screen and the Manual Screen. KVAL Commander III Operation Manual 5-17...

  • Page 160: Option Bc: Ball Catch

    Ball Catch Ball Catch Motor and Drill: Drills ball catch top edge (In-Feed) on RH Door Ball Catch Motor and Drill: Drills ball catch top edge (Out-Feed) on LH Door. KVAL Commander III Operation Manual 5-18...

  • Page 161: Option Sj: Split Jamb

    Load jamb assembly into machine. During process, press the Fire Side Nailer Button. Nailer Button: Push to The Stapler Assembly will move into place staple the split jamb and fire the staples. KVAL Commander III Operation Manual 5-19...
  • Page 162 Options KVAL Commander III Operation Manual 5-20...
  • Page 163 5-10 power up 3-6, 3-7 manual operation customer service interface 3-32 depth adjust operator’s tour calibration 4-24 top view options out-feed electrical panels key assemblies description 5-10 overview emergency shutdown KVAL Commander III Operation Manual...
  • Page 164 Safety Concerns 1-20 sensors types 5-13 voltage levels 5-13 six light panel description 3-35, 5-12 sequence list 3-35, 5-12 slow lock plate timing calibration 4-23 start machine button power up Start Sequence 3-13 tagout procedure 1-10 KVAL Commander III Operation Manual...
  • Page 168 Contacting KVAL Customer Service Phone and Fax: Mailing address: In the U.S and Canada, call (800) 553-5825 or fax Customer Support Department (707) 762-0485 Kval Incorporated Outside the U.S. and Canada, call (707) 762-7367 825 Petaluma Boulevard South or fax (707) 762-0485 Petaluma, CA 94952 Email: service@kvalinc.com...

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