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Kval DL-2DH Operation And Service Manual

Door light cut-out machine
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Innovation, Quality & Honesty
DL-2DH Door Light Cut-Out Machine
Operation and Service Manual
Published: 4/28/16

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Summary of Contents for Kval DL-2DH

  • Page 1 Innovation, Quality & Honesty DL-2DH Door Light Cut-Out Machine Operation and Service Manual Published: 4/28/16...
  • 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 DL-2HD Operation/Service 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 KVAL DL-2HD Operation/Service Manual...

  • Page 5: Table Of Contents

    Table of Contents Introduction to the DL-2DH Chapter 1 Chapter 1 at a Glance.............. 1-1 Overview of the DL-2DH............1-2 Options Available..................1-3 About this Manual .................1-4 Safety Sheet Sign-Off Sheet..............1-4 Safety First!................1-5 Safety Sheet Sign-Off Sheet..............1-5 Safety Terminology of Labels..............1-5 Safety Guidelines..................1-5...
  • Page 6 Quick Start Description ............2-6 Powering Up and Down the DL-2DH ........2-7 To Power Up the DL-2DH ..............2-7 Powering Down the DL-2DH..............2-7 Momentary Stop..................2-8 To Resume Normal Operation after a Momentary Stop......2-8 Operator Controls ..............2-9 Pneumatic Table and Edge Prep Controls..........2-10 Edge Prep Controls (Option) ..............2-11...
  • Page 7 Adjusting Cylinder Retraction Speed ............4-3 About a Typical Contactor Control ........... 4-4 About Contactor Troubleshooting ............4-5 Troubleshooting Electrical Problems ........4-6 If the Power Stops During Normal Operation........4-6 Troubleshooting with the Status Light Panel ......4-8 KVAL DL-2DH Operation/Service Manual...
  • Page 8 DL-2DH Door Light Machine...

  • Page 9: Chapter 1 At A Glance

    Chapter 1 at a Glance CHAPTER 1 Introduction to the DL-2DH This chapter provides an overview of the KVAL DL-2DH machine and important safety informa- tion to follow when operating the machine. Chapter 1 at a Glance Chapter 1 at a Glance ..................

  • Page 10: Overview Of The Dl-2Dh

    The standard pass line height of the DL-2DH is 33-1/2”. If the DL-2DH is to be used in a line with a Handler Door Feeder or any Kval assembly machine option P may added specified to raise the feed height to 38-1/2"...

  • Page 11: Options Available

    Also includes all air pipe, pipe fittings, clamps, flexible hose, and bracket bolted to the DL-2DH frame to support the dust collection piping. 13 foot ceiling height required for dust collection piping. Cus- tomer is responsible suspending the the overhead dust collection pipe to the building.

  • Page 12: About This Manual

    High-Frequency Route 11 HP High-Frequency 3-phase motor replaces belt driven spindle. Option: Tooling and Lubricant Package Please review with your KVAL consultant to determine your needs. Option: Spare Parts Package Please review with your KVAL consultant to determine your needs.

  • Page 13: Safety First

    See “Safety Sign-Off Sheet” on page 1-19. 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 14 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 DL-2DH Series Operation/Service Manual...
  • Page 15 This should be done in accordance with applicable state and/or federal code requirements. Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions. KVAL DL-2DH Series Operation/Service Manual...
  • Page 16 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 17: Lockout-Tagout Guidelines

    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 DL-2DH Series Operation/Service Manual...

  • Page 18: Lockout Tagout Procedure

    Lock and Tag out Insert Lock into hole. OFF position Note: When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided. KVAL DL-2DH Series Operation/Service Manual 1-10...

  • Page 19: Lockout Tagout Air Supply

    The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized. The tags must be destroyed and the locks and keys returned to the lockout center. KVAL DL-2DH Series Operation/Service Manual 1-11...

  • Page 20: 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 1-14. Check Controls Confirm that all switches are in the “OFF”...
  • Page 21 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 DL-2DH Series Operation/Service Manual 1-13...

  • Page 22: Getting Help From Kval

    Ask about this procedure when calling are service team 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.
  • Page 23 • With what equipment is the unit interfaced? • What was the application? • What was the system environment (temperature, spacing, contaminants, etc.)? Call Kval customer support for a Return Material Authorization (RMA). When you call: • Have the packing slip or invoice numbers available.

  • Page 24: 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 25 Session code: An internal number to track this machine. It is auto filled. Your Name Field: Enter your name. The KVAL tech- nician will use this field to identify this machine. Description: Enter machine Serial number and issue.
  • Page 26 How to Download the Service Application Page Intentionally Left Blank KVAL DL-2DH Series Operation/Service Manual 1-18...

  • Page 27: Safety Sign-Off Sheet

    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 28 Safety Sign-Off Sheet KVAL DL-2DH Series Operation/Service Manual 1-20...

  • Page 29: Chapter 2 Operation Of The Dl-2Dh

    Operation of the DL-2DH This chapter describes components, assemblies, and the user interface of the KVAL DL-2DH Sys- tem. The content is geared to help operators understand the basic operation of the DL-2DH Chapter 2 at a Glance Operator’s Tour ......................2-2 Standard .........................2-2...

  • Page 30: Operator's Tour

    Operator’s Tour Operator’s Tour This section contains a general overview of the assemblies and options on the DL-2DH. Standard Back Side Head Motor Cutting Head Controls Cutting Controls Stop Head Back Side Cutting Head Stop Front Side Infeed Cutting Head...

  • Page 31: Option D: Edge Prep

    The automatic blow off consists of a bank of high-pressure air nozzles to clean dust and debris as the door feeds out of the DL-2DH. To manually turn off the air, use the slide value located on the side of the machine.

  • Page 32: About The Electrical Panels

    About the Electrical Panels About the Electrical Panels The DL-2DH has a Main Electrical Panel and Nodes on the Cutter Head and the Frame. This sec- tion is an overview of the electrical components. Refer the machine's electrical prints for in-depth information.

  • Page 33: 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 DL-2DH system. See “Troubleshooting with the Status Light Panel” on page 4-8., for information Note: on using this panel for troubleshooting.

  • Page 34: Quick Start Description

    Quick Start Description Quick Start Description Ensure factory air is present at machine and the DL-2DH main air supply valve is turned on. Install tooling Set up the door positioning. Set up the cuts: • Set up the edge prep (optional) •...

  • Page 35: Powering Up And Down The Dl-2Dh

    Powering Up and Down the DL-2DH Powering Up and Down the DL-2DH This section describes how to power up and to power down the DL-2DH Powering up the system includes: • Applying power to the entire system. • Starting the Control Circuit.

  • Page 36: Momentary Stop

    Powering Up and Down the DL-2DH Momentary Stop The momentary stop switch is activated by pressing the Stop button located on the motor carriage Momentary Stop Start Button When an Momentary Stop is activated, cutting stops, power is no longer supplied to the cutter motor.

  • Page 37: Operator Controls

    Operator Controls Operator Controls Set of Y Template Bars: 10 included. See “About Y Axis Tem- plate Bar(s)” on page 2-16. Stop Motor Controls Edge Prep Controls Pneumatic Controls Head Controls KVAL DL-2DH Series Operation/Service Manual...

  • Page 38: Pneumatic Table And Edge Prep Controls

    Drill (In Out Down): This is a (3) position air switch that controls the location of the bolt drill. • Out: the Drill Carriage pivots away from the door’s edge • In: The Drill Carriage swing in to the door edge. • Down: Locks the Drill into Position KVAL DL-2DH Series Operation/Service Manual 2-10...

  • Page 39: Edge Prep Controls (Option)

    Turn switch to the left position to start drill motor, turn it to the center to turn drill off. Turn switch to the right to turn plate router motor on. Turn it to the center to turn router off.Drill KVAL DL-2DH Series Operation/Service Manual 2-11...

  • Page 40: Motor Controls

    • Cutter Up: Pushing the button in moves the cutter up out of the cutting position. • Locks: The X and Y lock switches control the X and Y movement of the cutting head. Switch positions are defined on the next page KVAL DL-2DH Series Operation/Service Manual 2-12...
  • Page 41 Y axis move only. Y Axis X Axis Locked Y DOWN, X UP: X and Y both unlocked. Y Axis X Axis Y UP, X DOWN: X and Y both locked. Y Axis Locked X Axis Locked KVAL DL-2DH Series Operation/Service Manual 2-13...

  • Page 42: Dl-2 Setting Up For A Cut

    DL-2 to calibrate. Door Stop The standard DL-2 has one doorstop set to customer deadbolt specifications, and a spring-loaded Face Bore stop. Both stops are factory set if your company provided specifications to KVAL during manufacturing. 8.0’ Door Stop 6.8’...

  • Page 43: Cutter Head Stops

    Cutter Head Newer DL-2 models are equipped with mist oilers to maintain proper arbor lubrication. Use AW 32 Hydraulic oil KVAL P/N SYSLUBG. Door Thickness The DL-2 is equipped to handle 1 3/8” and 1 ¾” thick doors. If you run 2 ¼” thick doors, the red hold up wheel bars, and the end rolls need to be adjusted downwards.

  • Page 44: About Set Collars And Templates

    • Tighten the set collars. • Make a test cut, and adjust as necessary. If you have templates for rectangular lights. • Place the template in the DL-2DH. • With power off guide the carriage along the pattern. • At the four corners of the light pattern position a set collar, and tighten.

  • Page 45: About Face Bore Templates

    2-3/8" and 2-3/4" backsets. Y- Axis Template Bar Set-up Kval recommends that only one door light set-up be used per template bar. However, it is possible to set the template bar up for different door widths with the same cutout dimensions in some cases.

  • Page 46: Adjusting A Y Template Bar

    Sample Y Axis Template Bar Adjusting a Y Template Bar Adjust first set collar with inboard edge approx. 1-1/8" from end of shaft. Place bar in index assembly with collar butted against out-board face of shaft holder. KVAL DL-2DH Series Operation/Service Manual 2-18...
  • Page 47 Trap bar in place by adjusting a second collar on opposite face of shaft holder. Col- lars must be 1" apart center-line to center-line Kval recommends one set-up per shaft. There may be problems setting up a single shaft to accommodate more than one door width.
  • Page 48 Set collar using steps 4 & 5 for the out-board edge of the 2nd light. Setting-up for only one light opening is just a matter of not installing the two center collars that create the space between lights. KVAL DL-2DH Series Operation/Service Manual 2-20...

  • Page 49: Using Templates

    Using Templates Using Templates The DL-2DH is designed to use templates provided by Windows manufacturers. Templates are typically 1/2” plywood cut the same size as the door. The templates are also typi- cally made for 1-1/2” nose follower and a 1/2” bit.

  • Page 50: Positioning The Template

    Using the wrong index holes will result in an off centered light cut-out Index Holes 2-10 Custom Illustration shows a standard DL-2, Stops can be located at the feed in as well. KVAL DL-2DH Series Operation/Service Manual 2-22...

  • Page 51: Template Drill Jig

    Place the template jig squared to the bottom comer (closest to the operator) of the template. Cut off or notch the template jig at the point the top of the door intersects with the jig. KVAL DL-2DH Series Operation/Service Manual 2-23...
  • Page 52 Using Templates KVAL DL-2DH Series Operation/Service Manual 2-24...

  • Page 53: Chapter 3 Maintenance Of The Dl-2Dh

    This chapter describes preventative maintenance steps for KVAL DL-2DH. The content is geared to guide technicians to keep a regular maintenance schedule for your KVAL machine. Keeping your KVAL machine maintained is an important piece for successful operation of your door pro- duction process.

  • Page 54: Maintenance Schedule

    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 part# SYSLUBG) Six Month Preventive Maintenance Operation Description Clean Wash filter and lubricator bowls with soapy water.

  • Page 55: Lubrication Schedule

    Recommended Schedule Recommended Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation Dura-Lith Grease (KVAL P/N Lube EP-2) Flange Block Bearing Ball Screw Every 80 Hours of Machine Operation Air Line Lubricator One drop of oil every 2 or 3 cycles Check Either lubricant listed below is approved to use.

  • Page 56: Lubrication Requirements

    If the bearing is equipped with a grease fitting (Zerk Fitting), it should receive 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N Lube EP-2) every 250 hours of operation. Note: Bearings without grease fittings have been pre-lubricated at the factory and do not require further lubrication.

  • Page 57: Gear Motor Lubrication Requirements

    MOBILUBE HD 80 W-90 or equivalent. Ball Screws (If Applicable) All ball screws should be lubricated Dura-Lith Grease (KVAL P/N Lube EP-2) for every 80 hours of operation. At each lubrication grease should be pumped into the fitting until clean grease comes out around the ball screw.

  • Page 58: Adjusting The Air Line Lubricator

    Repeat this same procedure for the back section and other trouble areas. It is recommended to check the lines every week to two weeks. KVAL DL-2DH Series Operation/Service Manual...

  • Page 59: Changing Or Adjusting Bits

    With cutter in the up position, place bit into collet loosely. Push cutter head over lock bore template and adjust cutter bit so it clears the tem- plate and reducing ring by 1/16”. Tighten collet securely. KVAL DL-2DH Series Operation/Service Manual...

  • Page 60: Adjusting Drill Unit

    • Insert a 5/8” stop pin into threaded pin holder. • Insert a 5/8” stop pin on each side of the horizontal cylinder. • BOLT PLATE ROUTER is now set up to cut a 1 X 2 -¼” BOLT PLATE in a wood rail. KVAL DL-2DH Series Operation/Service Manual...
  • Page 61 Notes:...

  • Page 62: Chapter 4 Troubleshooting The Dl-2Dh

    Troubleshooting the DL-2DH This chapter describes troubleshooting steps to help technicians solve issues that may occur with your KVAL machine. If help is needed, call or contact our KVAL Service team at (800) 553-5825 or http://www.kvalinc.com. Refer to the Air and Electrical drawings provided with delivery of the machine.

  • Page 63: Dl-2Dh Sensors

    DL-2DH Sensors DL-2DH Sensors On the DL-2DH, sensors provide input to the PLC. The application in the machine is similar to a micro-switch. How Sensors Work On the DL-2DH, sensors provide input to the PLC as part of the automation of the door cutting process, including feed through, door clamping, and door location.

  • Page 64: Important Notice About Adjusting Cylinder Speed

    Adjusting Cylinder Extend Speed Adjusting Cylinder Retraction Speed Note: If Installing a new flow control assembly, shut down the flow control and back out 4 to 5 turns. this position is a good starting point for kine adjust. KVAL DL-2DH Series Operation/Service Manual...

  • Page 65: About A Typical Contactor Control

    Common DC - Thermal Control Coil for OverLoad 120 Vac. Should measure Line Voltage here Motor Schematic Drawing of Contactor and Thermal Overload Block Diagram of a Common Contactor Circuit FIGURE 4- 4. KVAL DL-2DH Series Operation/Service Manual...

  • Page 66: About Contactor Troubleshooting

    If the same overload keeps tripping, verify condition. Follow circuit path using the E-Drawing as a reference. a.Common issues: Check for bad wire, bad motor, or if load is too great for cur- rent draw. KVAL DL-2DH Series Operation/Service Manual...

  • Page 67: Troubleshooting Electrical Problems

    Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Panel. If copies NOTE: are unavailable, contact the KVAL Service Department. Have model number and serial number of machine readily available. Warning The following checks require the electrical panel to be energized.
  • Page 68 Note: Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain, blocked photo sensors etc.) Note: If a solenoid valve is suspected, and not cleared in the air checks section (see), it can be electri- cally jumped to check operation. KVAL DL-2DH Series Operation/Service Manual...

  • Page 69: Troubleshooting With The Status Light Panel

    STEP 4: Stop (Amber) If light is OFF go to item page 4-10. STEP 5: Start (Amber) If light is OFF go to item page 4-11. STEP 6: 24VDC (Green light is OFF go to item page 4-12. KVAL DL-2DH Series Operation/Service Manual...
  • Page 70 X1 and X2. If no power is measured it is a bad transformer. b.If there is power at X1 and X2, check the other side of the fuse. If now power, replace the fuse. KVAL DL-2DH Series Operation/Service Manual...
  • Page 71 Start button. If no voltage, check the Stop button to make sure it is all the way out and not stuck in, then check the contact to make sure it is closed. If still no voltage, check the wiring. KVAL DL-2DH Series Operation/Service Manual 4-10...
  • Page 72 #2 and #5. If there is 120 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wiring or the contact on the Start button. KVAL DL-2DH Series Operation/Service Manual 4-11...
  • Page 73 Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block. Reinstall the (+ 24V positive) wires one by one, checking for +24VDC after installing each. If at any point no voltage is found trace the last reinstalled wire and check for shorts. KVAL DL-2DH Series Operation/Service Manual 4-12...
  • Page 74 Notes:...
  • Page 75 1-10 power up troubleshooting product return procedure 1-14 quick start 990-H remote operation, setting up machine for 1-16 return material authorization (RMA) 1-14 returning the product to Kval 1-14 safety guidelines Safety Sign Off Sheet KVAL DL-NCD Operation/Service Manual...
  • Page 76 Index KVAL DL-NCD Operation/Service Manual...
  • Page 78 Notes:...
  • Page 79 Notes:...
  • Page 80 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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