Page 1 Operation Manual Innovation, Quality & Honesty DL-NCD Door Lite System Operation Manual Published: October 21, 2019...
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-NCD 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 DL-NCD Chapter 1 Chapter 1 at a Glance.............. 1-1 Overview of the DL-NCD ............1-2 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 Sample Oval Cut.................2-30 Operation of the Machine Line Chapter 3 About the DL-NCD..............3-2 About the DL-NCD Process............. 3-3 Initial Powering Operations for the Machine Line ....3-4 Operator’s Station .................3-4 How to Power Up the Machine Line .............3-5 Home the Machine Line................3-6 How to Power Down the Machine............3-6...
Page 7 About the Main Control Screen..........3-12 About the Main Control Section ............3-12 ......................3-13 About the Width Adjust and Feed Control ..........3-14 About the DL-NCD Manual Servo Control Screen....3-16 Manual Control Operation..............3-17 About Manual Tool Changer Control...........3-18 About the Main Control Section ............3-19 About Tool Usage ..............
Page 8 Table of Contents About The Calibration Box..............4-6 About Restore Points................4-7 About the DL-NCD Calibration Screen ........4-8 DL-NCD Calibration Screen..............4-8 Calibration Selections ................4-8 About Calibration Sequence ............ 4-9 Calibrate the Length and Width ............4-9 Process to Calibrate the Length and Width ..........4-9 Step 2: Calibrate the Face Tools..........
Page 9 How to Change a Tool Bit ..............5-14 About Field Safety Scanners ........... 5-16 About the Drop-Out Area ............5-17 Drop-Out: Slide Style ................5-17 Drop-Out: Box Style ................5-17 About the Electrical Panels............5-18 About the Frame Node ...............5-20 About the Cutter Node ................5-20 KVAL DL-NCD Operation Manual...
Page 10 Table of Contents KVAL DL-NCD Operation Manual...
Page 11: Chapter 1 At A Glance
This section describes the method to page 1-20 Getting Help from KVAL contact the KVAL service center for help. The section includes how to get informa- tion from the specification plate tor pro- vide to KVAL, service center hours, and...
Page 12: Overview Of The Dl-Ncd
Kval. With Purchase, the Customer may submit up to Eight(8) door specifications/cutout templates which will be pre-programmed prior to shipment. Kval suggests the customer submit their more difficult templates, such as ovals, for the Kval programmers to implement.
Page 13 Furthermore, KvalCAM offers increased supportability and troubleshooting capabilities. Newly developed error codes and code definitions quickly identify any problems to the operator or Kval tech. For more information regarding the full functionality and benefits of KvalCAM, please refer to your Kval Sales Engineer.
Page 14: About This Manual
Overview of the DL-NCD 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 15: 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 16 All cylinders on machine are under high pressure and can be very dangerous when activated. Before performing any mainte- nance or repairs on this machine turn off the main air disconnect. Lockout and tagout this connection. See “Lockout Tagout Procedure” on page 1-10. KVAL Operation Manual...
Page 17 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 Operation Manual...
Page 18 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 19: 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 Operation Manual...
Page 20: Lockout Tagout Procedure
Turn Switch to the 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 Operation Manual 1-10...
Page 21: 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 Operation Manual 1-11...
Page 22: 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 “” on page 1-20. Check Controls Confirm that all switches are in the “OFF” position. Please be advised that some com- ponents of the machine may start automatically when energy is restored.
Page 23 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 Operation Manual 1-13...
Page 24: Getting Help From Kval
Getting Help from KVAL Getting Help from KVAL Before you seek help, first try the troubleshooting procedures. Follow the procedures below. If you are unable to resolve the problem: Locate the machine’s Specification Plate and record the serial number, 3 phase volts, electrical print number, and air print number.
Page 25: 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 26: 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 27 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 28 How to Download the Service Application KVAL Operation Manual 1-18...
Page 29: 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 30 Safety Sign-Off Sheet KVAL Operation Manual 1-20...
Page 31: Summary Of The Kvalcam Interface
2-3 About the Libraries creation, job editing, loading templates, and Screen verifying job creation. Description of the Machine Line Screen.: page 2-14 About the Machine Line Includes Line Control Buttons, Queued Jobs Screen and Machine Activity. KVAL Operation Manual...
Page 32: Libraries And Machine Line Screens
See “About the Libraries Screen” on page 2-3. Machine Line View the entire process of the machine line, queued jobs, quantity and remaining doors, and status of each machine. Some line control is available. See “About the Machine Line Screen” on page 2-14. KVAL Operation Manual...
Page 33: About The Libraries Screen
Door Job ing of the door can be processed using this information. Detail Feature Group Door Job Saves Cut Information Saves Door Parameters Many Number of Feature Groups Allowed Load Work Onto Machines (Cut Doors) KVAL Operation Manual...
Page 34: Library Screens
Use the buttons at the bottom of the screen to create, clone, edit, or delete jobs or Feature Groups. Lock editing capabilities and refresh tabs are also available. Note: The have the same layout and storage for- Door Job and Features Group Library mat. KVAL Operation Manual...
Page 35: About The Feature Groups And Door Jobs
Jumps to the Job to Delete. to copy and add password to Creation Screen rename. edit the data- (The Most Common Path way base.(Customer to start the door Machining requested option) Process) KVAL Operation Manual...
Page 36: About Job Creation
, select the item from or Template button at the bottom of the the table, then select the Edit /View screen. button on the bottom of the page. bottom of the screen. Screen Shot of Job Creation FIGURE 2-1. KVAL Operation Manual...
Page 37: About The Job Name Menu
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. Note: Changes in the door parameters and door hand are reflected in the menu. Job Preview The door illustration will change in shape. KVAL Operation Manual...
Page 38: About The Feature Tree Menu
Validation • : 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 Operation Manual...
Page 39: 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 Operation Manual...
Page 40: 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 Operation Manual 2-10...
Page 41: About The Control Buttons
Door Job. The background program will translate the param- eters 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 Operation Manual 2-11...
Page 42: 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 Operation Manual 2-12...
Page 43 Select the 3 D Tab to display a three dimensional view of the Door Job. Right click the mouse to control the movement of the 3 D display. are color coded and listed on the display. Preview Surfaces KVAL Operation Manual 2-13...
Page 44: About The Machine Line Screen
For each machine, a table shows job name, quantity of remaining 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 Operation Manual 2-14...
Page 45 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 Operation Manual 2-15...
Page 46 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 Operation Manual 2-16...
Page 47 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 Operation Manual 2-17...
Page 48: 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 49: Definitions
Inputted values by the user for an intended feature. The input is interpreted by the program and passed through a validation scheme for all machines in a line to determine if the intended cut is capable of being run (see valida- tion). KVAL Operation Manual 2-19...
Page 50 Calibrations, or Libraries (e.g. material types) will produce unex- pected or potentially harmful results to the machine and/or operator. Some cuts in fringe cases may pass validation that result in non-conform- ing cuts (cut does not match visual representation). KVAL Operation Manual 2-20...
Page 51: Appendix: 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 Operation Manual 2-21...
Page 52: 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 Operation Manual 2-22...
Page 53: 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 Operation Manual 2-23...
Page 54: Appendix: About Validation
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 Operation Manual 2-24...
Page 55: About The Validation Screen
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 Operation Manual 2-25...
Page 56: About The Litecutout Feature Detail
Feature Tree Select from the drop down menu and add a LiteCutout Feature Type Feature .add a Feature Name. Name Select the Edit Button. Add Group Add Child Select LiteCutout and Name Select the Edit Button KVAL Operation Manual 2-26...
Page 57 If Import DXF Button needed, manipulate the shape. Import DXF file In this example, an oval DXF file was imported. or add the file into by selecting the KvalCAM OK Button. KVAL Operation Manual 2-27...
Page 58 About the LiteCutout Feature Detail Input to put the cut onto the door. WLocation LLocation If finished with editing the , run the door. Door Job KVAL Operation Manual 2-28...
Page 59: About The Litecutout Screen
Screen. LiteCutout About the Work Areas Zoom In and Out with Mouse Move shape vertically and horizontally with Slide Bars. Select a vertex (point on the cutting path) and manipulate the shape. Expand or collapse windows KVAL Operation Manual 2-29...
Page 60: About The Work Area Coordinates
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 Operation Manual 2-30...
Page 61 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 Operation Manual 2-31...
Page 62 About the LiteCutout Feature Detail KVAL Operation Manual 2-32...
Page 63 Machine Start Summary A quick summary of running a door through the machine. page 3-10 About Machine Process Describes the process of the machine. page 3-11 About the DL-NCD Screen Descriptions of the Screens that interface with the DL-NCD KVAL Operation Manual...
Page 64: About The Dl-Ncd
About the DL-NCD About the DL-NCD of a door for Door DL-NCD is a computer controlled machine designed to precisely machine the face Light patterns and lock patterns. Below is a typical location of the in a Door Processing DL-NCD Line.
Page 65: About The Dl-Ncd Process
About the DL-NCD Process About the DL-NCD Process Ensure the Start-up process has been completed (See page 3-4), that the machine has been Homed doors are loaded to be processed, and the area is clear and safe to start production.
Page 66: Initial Powering Operations For The Machine Line
Down machines. Start and stop the door pro- cess, pause doors in the Feeder and Stacker. Emergency Stop. See “Initial Powering Operations for the Machine Line” on page 3-4 Keyboard: Enter data and interact with Touch Screen. KVAL Operation Manual...
Page 67: How To Power Up The Machine Line
See “Appendix: Descrip- tion of the Six Light Panel” on page 3-30 Note: If a status light does not turn on during the power up process, see the trouble shooting chapter in the Service Manual. KVAL Operation Manual...
Page 68: Home The Machine Line
Switch the green switches for each CONTROL CIRCUIT machine to the OFF position. KVAL also recommends that you turn the disconnect switches on the electrical cabinets to OFF; this helps reduce possible damage resulting from power surges from electrical storms.
Page 69: About Emergency Shutdown And Recovery
• Laser Safety Scanners: These are located on the front of the machine. These assemblies create an invisible safety field protecting the Operator from entering the cutting area of the machine. • Safety Curtain: This creates an invisible curtain on all entrances to the DL-NCD. KVAL Operation Manual...
Page 70: Machine Line Start Summary
Note: If needed, create or add a fea- ture to the door job Verify or Modify Job Add the Quantity of Doors in the Door Qty: Box Enter Qty. Select (Add to Queue) Select the button. Add to Queue KVAL Operation Manual...
Page 71 Red Stop button, Shut down the operating system, by selecting from the Shutdown Desktop. After computer has fully shutdown, turn off the Green Control on the Operators Station. Transformer lever Turn OFF the the Electrical Panels. Red Power lever KVAL Operation Manual...
Page 72: About Machine Status Feedback
When activated, the tab will highlight. Note: At the top of the screen, the revision of software is dis- played. KVAL Operation Manual 3-10...
Page 73: About The Dl-Ncd Screens
DL-NCD. Manual Servo Control Operate the DL-NCD manually by way of servo control. See See “About the DL-NCD Manual Servo Control Screen” on page 3- Tool Usage Table to show the tool usage. See See “About Tool Usage” on page 3-20.
Page 74: About The Main Control Screen
Select the . At the Main Screen, control the all the operations of the machine to Main Control Tab process a door. Main Screen of DL-NCD FIGURE 3-1. About the Main Control Section Home Machine This button starts the home sequence on the machine, which scans to find a physical reference point on the frame.
Page 75 (X,Y,and Z) and the width Routine Speed Adjust the speed of the cut. Press buttons to use the graduated speeds or select box and enter a desired speed. The speed can be changed during real time processing. KVAL Operation Manual 3-13...
Page 76: About The Width Adjust And Feed Control
Press and hold the button to close the width adjust carriage. To stop the Move Close: carriage, release the button. The carriage will also stop if the negative travel limit eye is activated. • Speed%: Enter the desired speed. KVAL Operation Manual 3-14...
Page 77 Note: Probe locations on this machine can be found in Chapter 5 of this manual. Note: When the Length and Lock Edge Probes are disabled, door length and lock specifications are derived from the Door Job. KVAL Operation Manual 3-15...
Page 78: About The Dl-Ncd Manual Servo Control Screen
About the DL-NCD Manual Servo Control Screen About the DL-NCD Manual Servo Control Screen Select the At this screen, control the servos manually and run a process to Manual Control Tab. fine tune the tool pickup routine. Manual Control Screen for the DL-NCD FIGURE 3-2.
Page 79: Manual Control Operation
About the DL-NCD Manual Servo Control Screen Manual Control Operation For Each Axis: • Reverse: Press and hold the Reverse button to reverse the motion of the carriage. Release the button to stop the carriage. The carriage will also stop if the negative travel limit eye is activated.
Page 80: About Manual Tool Changer Control
About the DL-NCD Manual Servo Control Screen About Manual Tool Changer Control This routine aids in ensuring the tool pick up and drop off locations between the r and are matched up. Cutter Head Tool Holde Tool Holder Rack When activated, the...
Page 81: About The Main Control Section
About the DL-NCD Manual Servo Control Screen About the Main Control Section Edge Servo Control Adjust the speed of the Edge Cutter in the Y axis (vertical) KVAL Operation Manual 3-19...
Page 82: About Tool Usage
Start Date: This is the date ton has been selected for replaced, select the Clear the tool was changed. This that tool. button to reset to zero. is set by the Clear Button. Tool Usage Table FIGURE 3-4. KVAL Operation Manual 3-20...
Page 83: About The Tool Path Preview Test Tab
Step 3 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. KVAL Operation Manual 3-21...
Page 84: About The Tool Config Tabs
• Chisels: Can change peck count (start of cut), corner location, and rate of machin- ing. Select Tab Unlock, Lock, and Save Data Pop-Up Menu Enter parameters to tune the method of List of Tools Available machining KVAL Operation Manual 3-22...
Page 85: Unlock The Tool Slot Configuration
Below are samples of the pop-up windows Enable Check Box available. Sample Drill Configuration Pop-Ups Drill Pop-up Sample Drill Pop-up Disabled Sample Sample Router Configuration Pop-Ups Router Pop-up Disabled Sample Router Pop-up Sample Sample Chisel Configuration Pop-Ups KVAL Operation Manual 3-23...
Page 86: About Tool Locations
About Tool Locations Tool locations are identified by slots. See the figures below for the locations and identifications. Note: Below are factory suggested locations. Identification of Slots can be altered through this menu. Face Tools Lock Tool KVAL Operation Manual 3-24...
Page 87: About Using Tool Configuration
Length Update the data in the Cutting Tool Config Group Length Important: The accuracy of the data Tool Config important. Any errors could damage tooling or prod- uct. Tool Point Length KVAL Operation Manual 3-25...
Page 88: About Entering Data Into The Pop-Up Menu
Insert specifications of the tools being used to make the cuts. Ability to name the tools to user defined descriptions. Customize the tools to reflect the actual tool parameters, making the most accurate cuts. Ability to define cut operation. KVAL Operation Manual 3-26...
Page 89: About The Lock Block Tab
Use if the block is mirrored on the hinge side of the door. Also on Hinge Side: Select the button to store the Lock Block Parameters Save Hinge Side Lock Side Length (15 '') Width (8 '') Bottom Of Door To Block (36 '') KVAL Operation Manual 3-27...
Page 90: About The Status And Log Screens
(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 3-5. KVAL Operation Manual 3-28...
Page 91: 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 92: Appendix: Description Of The Six Light Panel
ACR Relay is latched. 24VDC This light comes on once the ACR is latch and the 24VDC power Supply is working Stop – Control Power Fourth First Start – Overload Relay Fifth Second E-Stop 24VDC – Third Sixth KVAL Operation Manual 3-30...
Page 93: Appendix: About Backing Up The Data
Appendix: About Backing up the Data Appendix: About Backing up the Data Right Click the KVAL Icon at the bottom of the screen to display this menu. Exit: Click to close the running Kval Cam program. to save all data from Backup Logs: Click to save the the machine operation.
Page 94 Appendix: About Backing up the Data KVAL Operation Manual 3-32...
Page 95 About the Calibration Tabs page 4-3 Descriptions of the Calibration Tabs. How to Enter Calibration Data page 4-6 Descriptions of how to use the calibration screens About the Calibration Screen page 4-8 Descriptions of the calibration available. KVAL Operation Manual...
Page 96: 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 97: About The Calibration Tabs
Log Screens reporting. 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 98: 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 Operation Manual...
Page 99: Enter A Positive Or Negative Number
Stand at the Lock Side of Door, point at the edge of the door with the left hand rule to determine axis direction Door Face Axis Directions Stand at the Lock Side of Door, point down at the face of the door with the left hand rule to determine axis direction KVAL Operation Manual...
Page 100: 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 101: About Restore Points
Name and enter to save To Load or Delete a Restore Point: Select the restore point from the menu Select the button to use the calibration. Select the button to load Load Load Select the button to delete the point. Delete KVAL Operation Manual...
Page 102: About The Dl-Ncd Calibration Screen
About the DL-NCD Calibration Screen About the DL-NCD Calibration Screen contains a list of calibration adjustments. Select the located Calibration Screen DL-NCD Tab on the left hand side of the machine, then select the to jump to this menu. Enter...
Page 103: About Calibration Sequence
Measure the length of the door and capture it. Measure the width Create a input the actual measurements of the door. Door Job, Add Actual Mea- surements of the Door KVAL Operation Manual...
Page 104 Compare the actual measured data with the calculated data. If the measurement feedback is less that the actual measurement, width input a neg- ative value If the measurement feedback is that the actual measurement, length less input positive value KVAL Operation Manual 4-10...
Page 105: Step 2: Calibrate The Face Tools
Once the cut has been made, check the parameter (length and width) of the cut. Increase or decrease the diameter offset to match the parameters of the FaceRectangle Negative Offset Increases Size Positive offset Decreases Size KVAL Operation Manual 4-11...
Page 106: Step 3: Calibrate The Face Carriage
“About Using Tool Configuration” on page 3-25. Face Carriage Axes Calibrations Using the left hand rule, verify the the X, Y, and Z axes. Refer to the figure below for axis move- ment direction. KVAL Operation Manual 4-12...
Page 107: Process To Calibrate The Face Carriage Head
• If the plunge cut is out of specification, check the Configuration Menu Face Axis Direction Z-Axis----Adjust update the Configuration Menu. To determine axis direction. Stand at the Lock Side of Door, point down on the face of the door with the left hand rule. KVAL Operation Manual 4-13...
Page 108: Step 4: Calibrate The Lock Edge Probe (Option)
Y-Axis This is a visual test. Run a Door Job. Check the Depth Probe Pad position as it touches the door edge. Pad on probe should cover at least 50% of the door edge. Probe Pad KVAL Operation Manual 4-14...
Page 109: Process To Calibrate The Probe Depth
If a value is displayed, enter a value to zero the probe reading. negative negative Run the door and verify the displayed feed back is zero. KVAL Operation Manual 4-15...
Page 110: Step 5: Calibrate Lock Edge Tools (Option)
Z-Axis To determine axis direction. Stand at the Lock Side of Door, point at the lock edge of the door with the left hand rule. KVAL Operation Manual 4-16...
Page 111: Step 6: Calibrate The Tool Holder
. At these step intervals, the operator establishes best tool position for the Rack Tool Holder Tool Rack. To initiate the sequence, go to the and locate the menu. Manual Control Tab Manual Tool Changer Status Message Box ON/ OFF and Step Control Select Tool KVAL Operation Manual 4-17...
Page 112: Axis Direction
“About the Manual Tool Change Mode” on page 4- Select the to turn it ON. Step Mode Button Select the desired tool in the section. Follow the text directions displayed Select Tool in the Status Message Box KVAL Operation Manual 4-18...
Page 113 Holder Tool At completion, verify that the tool is picked up from the and locked Tool Rack into the and the tool is placed Tool Holder and released into the Tool Rack. KVAL Operation Manual 4-19...
Page 114: Step 7: Calibrate The Slug Knockout
Door Job FaceRectangle to the Door Job Queue After the cut has been completed, verify the knockout plunge hits at the center of the cut. Adjust the offsets until plunge is centered. X-Axis Y-Axis KVAL Operation Manual 4-20...
Page 115: Step 8: Calibrate The Clamp
Enter the desired width of the fence in unclamping mode. Slide door into the machine and firmly press it against the fixed fence. There should be about 1/4" of a gap from the movable fence and the door edge. Repeat until condition has been met. KVAL Operation Manual 4-21...
Page 116: Step 9: Calibrate The Door Stop
Step 9: Calibrate the Door Stop Step 9: Calibrate the Door Stop About the Stop 1 Calibration adjust the calibration The calibration is to be used by trained Service Technicians. Stop 1 KVAL Operation Manual 4-22...
Page 117: Appendix: Servo Motor Drive Assembly Locations
Y-Axis Servo Motor Y-Axis Servo Motor (Lock Edge Prep) Z-Axis Servo Motor (Main Cutter) X-Axis Servo Motor(1 of 2) Width Servo Motor X-Axis Servo Motor(2 of 2) Connected to Speed Reducer. KVAL Operation Manual 4-23...
Page 118 Appendix: Servo Motor Drive Assembly Locations KVAL Operation Manual 4-24...
Page 119 CHAPTER 5 Tour of the DL-NCD This chapter describes components, assemblies, and the user interface of the KVAL DL-NCD Sys- . The content is geared to help operators understand the basic operation of the machine Chapter 5 at a Glance...
Page 120: Top View
Movable Cutouts Fence Stationary Fence Length Probe Tool Holder Rack Option R: Reverse Feed. Sensors Located Throughout Machine Side B Door can feed in at either end of machine. Top View of the DL-NCD FIGURE 5- 1. KVAL Operation Manual...
Page 121: Operator's Station
Similar to Control Circuit: Turns on the a soft boot-up on a computer.o circuit to give the machine power. E-Stop: Sops all functions and powers down the machine in an emergency situation. Operator Station FIGURE 5- 2. KVAL Operation Manual...
Page 122: About Side A And Side B
Some machines may have reverse feed. This allows inputting the door from either side. Check your machine for which options is included. Reverse Feed Normal Feed Side A Infeed/Outfeed Infeed Outfeed/Infeed Outfeed Side B About Side A and Side B FIGURE 5-3. KVAL Operation Manual...
Page 123: Around The Machine
The automatic blow off consists of a bank of high-pressure air nozzles to clean dust and debris as the door feeds in or out of the DL-NCD Note: To manually turn off the air, use the slide value located on the side of the machine. Air Nozzles for Blow Off of Debris FIGURE 5-5. KVAL Operation Manual...
Page 124: About Sensors
Door InFeed Sensor Door Width Sensor Before Outfeed Sensor Side B Before Stop Sensor Side Drill Mid Machine Probe Crash Door- In Sensor Probe Return Crash Sensor Sensor Sensor Sensor Sensor Locations on the Machine Frame FIGURE 5-7. KVAL Operation Manual...
Page 125: Homing And Limit Sensors
Z-In Tool Changer Z-Limit Pos Motor Release Tool Z Axis Sensors FIGURE 6. I-2002 (X Home) Y Limit Home Y Limit Neg Y Limit Pos X Limit Pos X Limit Neg X and Y Axis Homing Sensors. FIGURE 7. KVAL Operation Manual...
Page 126: About The Door Stop System
The door stops are controlled by an air cylinder. The stop will pop up when activated. A door pusher on the out feed end of the machine pushes the door up against the stop. The width adjust clamps the door tight. Door Stop Cylinder Stop Assembly FIGURE 5-1. KVAL Operation Manual...
Page 127: About The Probes
The feeler extends to touch the edge of the door to calculate the length of the door. Edge Lock Probe (Option): The feeler extends to touch the edge of the door to calculate the width of the door. Probe Locations FIGURE 5-2. KVAL Operation Manual...
Page 128: About The Cutter Head With Optional Side Drill Assembly
PLC. The Cutter Head Motor The motor is automatically driven to the to retrieve the Tool Holder Rack Tool Holder Knock-Out Assembly Width Probe Side Drill (Option Tool Holder Location Cutter Head FIGURE 5- 1. KVAL Operation Manual 5-10...
Page 129: About The Tool Holder Rack
Tool Holder Rack Note: If the tool changer does not detect a tool or if it encounters any other problem, the KVAL software will display an error message on the Operator’s Station monitor. Note: The retains the tool type in the Cutter Motor in memory.
Page 130: Removing The Tool Holder From The Cutter Head
Tool Holder firmly in place, use the other hand to push in the Tool Release Button. Do not let go of the Important: tool until the spindle clamp- ing assembly pulls the collet up into place! KVAL Operation Manual 5-12...
Page 131: Changing A Tool Bit And Using Tool-Change Tightening Fixture
Verify which type your machine uses. HSK Flange Spindle HSK Tool Holder Option Collet Collet V-Flange Spindle Tool Holder Option Assembled Tool Holder V-Flange Collet Collet Spindle Exploded and Assembled Views of Tool Holder FIGURE 5-2. KVAL Operation Manual 5-13...
Page 132: How To Change A Tool Bit
If bluing occurs, the collet must be scrapped. Reassemble the tool. When assembling, bottom out tool and back up about 1/4'' to ensure the correct distance. Tool should not stay bottomed out. Note: The collet should snap into place into the collet nut KVAL Operation Manual 5-14...
Page 133 Length Update the data in the , if needed. Cutting Tool Config Group Length Important: The accuracy of the data Tool Config is important. Any errors could damage tool- Group ing or product. Tool Point Length KVAL Operation Manual 5-15...
Page 134: About Field Safety Scanners
Start Machine the operator's station. the Machine. 2. Home Restart process. A Generalized sample of the laser safety Coverage Laser Warnings On some machines, laser indicators are used to set boundaries. Follow the manufacturers safety precautions. KVAL Operation Manual 5-16...
Page 135: About The Drop-Out Area
Drop-Out: Box Style Drop Out Box: The debris from the cutting process drops below to a crate. When crate is full, open the gate and pull it out and empty the debris. Drop-Out: Box style FIGURE 5-5. KVAL Operation Manual 5-17...
Page 136: About The Electrical Panels
• VFDs (Variable Frequency Drives) to interact with the cutter motor and the • Contains servo drives to interact with feed motors. the servo motors. DL-NCD Main E-Panel PLC (DL-NCD) 24V DC Supplies 24 VDC and 110 VAC Terminals Relays...
Page 137 About the Electrical Panels DL-NCD High Freq Panel 24 VDC and 110 VAC Terminals Relays Power Outlet PLC (DL-NCD) High Voltage Input Fuses VFDs Fixed Feed Move Feed Cutter High Frequency FIGURE 5-7. KVAL Operation Manual 5-19...
Page 138: About The Frame Node
The Cutter Node is connected to the PLC by way of the Frame Node and is located on the cutter head’s fixed side of the machine. This node interfaces with inputs and outputs of the cutter head to the PLC. PLC Interface Inputs and Outputs Cutter Node FIGURE 5-9. KVAL Operation Manual 5-20...
Page 139 About the Electrical Panels KVAL Operation Manual 5-21...
Page 140 3-7 load e-stop light delete description 3-30 return material authorization (RMA) 1-14 returning the product to Kval 1-14 high frequency panel description 5-18 Home Machine 3-12 Safe Mode Enabled/Disabled 3-13 safety guidelines 1-5 Safety Sign Off Sheet Safety Concerns 1-19...
Page 141 Index power up 3-5 Start Sequence 3-12 stop light description 3-30 tagout procedure 1-10 zero-energy start-up clean up 1-12 inspect 1-12 Kval DL-NCD...
Page 144 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...

Kval DL-NCD Operation Manual

Chapter 1 At a Glance

Appendix: Job Preview Examples

Appendix: about Validation

Appendix: Description of the Six Light Panel

Appendix: about Backing up the Data

Appendix: Servo Motor Drive Assembly Locations

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