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Kval DL-NCD Operation And Service Manual

Door light cut-out machine
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Innovation, Quality & Honesty
DL-NCD Door Light Cut-Out
Machine
Operation and Service Manual
Published: 8/21/2015

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Summary of Contents for Kval DL-NCD

  • Page 1 Innovation, Quality & Honesty DL-NCD Door Light Cut-Out Machine Operation and Service Manual Published: 8/21/2015...
  • 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 KVAL DL-NCD Operation Manual...

  • 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 .................1-2 Safety First!................1-3 Safety Sheet Sign-Off Sheet..............1-3 Safety Terminology of Labels..............1-3 Safety Guidelines..................1-3 Lockout Tagout Procedure..............1-7 Follow the P-R-O-P-E-R lockout rule of thumb........1-9...
  • Page 6 Powering Up and Down the DL-NCD ........2-21 How to Power Up the DL-NCD ............2-21 How to Home the DL-NCD ..............2-22 How to Power Down the DL-NCD............2-23 About Emergency Shutdown and Recovery ........2-23 ..............E-Stop Master Shut OFF2-23 To Resume Normal Operation after an E-Stop ........2-23 Description of User Interface Screens ........
  • Page 7 Lubrication Points ..............4-9 Frame and Feed Through..............4-9 Cutter Head ..................4-9 Troubleshooting the DL-NCD Chapter 5 DL-NCD Sensors ..............5-2 How Sensors Work ................5-2 Troubleshooting Sensors..............5-2 Locations of Sensors from the Out-Feed..........5-3 Locations of Sensors from the In-Feed..........5-4 Homing and Limit Sensors..............5-5 Troubleshooting the Air Cylinders..........
  • Page 8 DL-NCD Door Light Machine...

  • Page 9: Chapter 1 At A Glance

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

  • Page 10: Overview Of The Dl-Ncd

    When the DL-NCD is used as a drill de-burring on the bottom face may be required.

  • Page 11: Safety First

    See “Safety Sign-Off Sheet” on page 1-17. 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 12 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 1-7. KVAL DL-NCD Operation/Service Manual...
  • Page 13 Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tag out, or lock out the elec- trical and air pressure systems. This should be done in accordance with applicable state and/ or federal code requirements. KVAL DL-NCD Operation/Service Manual...
  • Page 14 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 15: 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 DL-NCD Operation/Service Manual...
  • Page 16 • 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 DL-NCD Operation/Service Manual...

  • Page 17: 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 DL-NCD Operation/Service Manual...

  • Page 18: 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 1-12. Check Controls Confirm that all switches are in the “OFF”...
  • Page 19 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-NCD Operation/Service Manual 1-11...

  • Page 20: Getting Help From Kval

    Chapter 3 “System IT Administration” on page 3-2, for more information. 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 21 • 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 22: 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 23 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 24 How to Download the Service Application Page Intentionally Left Blank KVAL DL-NCD Operation/Service Manual 1-16...

  • Page 25: 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 ser- vice@kvalinc.com.
  • Page 26 Safety Sign-Off Sheet KVAL DL-NCD Operation/Service Manual 1-18...

  • Page 27: Chapter 2 Operation Of The Dl-Ncd

    Operation of the DL-NCD This chapter describes components, assemblies, and the user interface of the KVAL DL-NCD Sys- tem. The content is geared to help operators understand the basic operation of the DL-NCD Chapter 2 at a Glance Operator’s Tour ......................2-2 About Sensors ......................2-4...

  • Page 28: Operator's Tour

    Operator’s Tour Operator’s Tour This section takes you on a tour of the DL-NCD machine. The figure below shows locations of selected areas, parts, and assemblies on the machine. In-Feed Sensors Located Opt G Throughout Barcode Scanner Machine Frame Node...
  • Page 29 Y Axis Servo X Axis Motor Servo Motor Cutter Motor Knock Out Piston Lubricator Tool Grip Tool Holder Machine Controls Operators Air Blow- station Off Valve Feed Air Blow Off Motors Out-Feed View FIGURE 2- 2. KVAL DL-NCD Operation/Service Manual...

  • Page 30: About Sensors

    FIGURE 2- 3. About Sensors On the DL-NCD, sensors provide input to the PLC as part of the automation of the door cutting process, including feed through, door clamping, and door location. It is important to keep the sen- sors cleaned and aligned to keep the door process running smoothly. There are two classifications of sensors on the DL-NCD: Photo Electronic and Inductive Proximity Sensor.

  • Page 31: About Motion Of Servo Motors: X,Y, Z, And W

    Y Servo Motor Red = Close W Axis Green= Open Y Axis W Servo Motor Red = Close Green= Open X Axis X Servo Motor Red = Reverse Green= Forward Servo Motor Motions FIGURE 2- 5. KVAL DL-NCD Operation/Service Manual...

  • Page 32: About The Door Stop System

    FIGURE 2- 6. About the Tool Holder The DL-NCD is equipped with a Tool Holder. When a door file is downloaded, the DL-NCD determines if a tool change is needed, based on door material defined in the door file. If a tool change is needed, the DL-NCD follows this process to change the tool: Moves to the Tool Changer.

  • Page 33: How To Change A Tool Manually

    Tool Holder and Air Nozzles to Clean FIGURE 2- 7. 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 DL-NCD retains the tool in the Cutter Motor in memory. If the tool is changed, while the machine is off, make sure that the tool matches the tool currently in the Cutter Motor.

  • Page 34: Changing A Tool Bit And Using Tool-Change Tightening Fixture

    Note: into place! Changing a Tool Bit and Using Tool-Change Tightening Fixture The section describes how to change the bit in a tool, use the Tool-Change Tightening Fixture, and enter data into the Tool Setup Group. KVAL DL-NCD Operation/Service Manual...
  • Page 35 Collet Housing snap into place after Flat Edges are collet is inserted into Orientated in Line base with Knob Fully Assembled Tool Tool-Change Tightening Fix- Locked in to Place ture Using Tool Grip FIGURE 2- 9. KVAL DL-NCD Operation/Service Manual...
  • Page 36 Setup Button. Tool Length Update the data in the , if needed. Tool Setup Group See “Tool Setup Group” on page 2‐34. Important: The accuracy of the data Tool Setup is important. Any errors could damage tool- Group ing or product. KVAL DL-NCD Operation/Service Manual 2-10...

  • Page 37: About Air Nozzles

    Air Nozzles for Blow Off of Debris FIGURE 2- 10. About Indicator Lights The Indicator light supplies quick identification of the status of the DL-NCD. See the table below for light status descriptions. Indicator Light Located on Top of the...

  • Page 38: About The Electrical Panels

    Operator’s Tour About the Electrical Panels The DL-NCD has a Main Electrical Panel, a High Frequency Panel and Nodes on the Cutter Head and the Frame. This section is an overview of the electrical components. Refer the machine's elec- trical prints for in-depth information.
  • Page 39 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 out- puts of the cutter head to the PLC. PLC Interface Inputs and Outputs Cutter Node FIGURE 2- 13. KVAL DL-NCD Operation/Service Manual 2-13...

  • Page 40: About The Cutter Head

    Cutter Head movements and cutting routines are driven by template software, manual input, and the PLC. Knock Out Piston Cutter Motor Router Bit Cutter Head FIGURE 2- 14. KVAL DL-NCD Operation/Service Manual 2-14...

  • Page 41: About The Drop Out Area

    The debris from the cutting process drops below to a roller assembly to collect the remnants in a common area. Warning: Be careful in this zone. Slugs will eject out and could cause body injuries if operator is not paying attention. Drop Drop Out Area FIGURE 2- 15. KVAL DL-NCD Operation/Service Manual 2-15...

  • Page 42: Description Of The Six Light Panel

    Operator’s Tour Description of the Six Light Panel The six lights on this panel indicate the status of the DL-NCD system. See “Troubleshooting with the Status Light Panel” on page 5-9, for information Note: on using this panel for troubleshooting.

  • Page 43: Option G: About The Barcode Scanning Hardware With Stationary Reader2-17

    Option G: About the Barcode Scanning Hardware with Stationary Reader Some machines have a barcode scanner integrated into the operating system of the DL-NCD. The barcode scanner reads the coded lock and light routing patterns off the bar coded door. The pro- gram loads the template to the user interface.The barcode scanner is mounted at the in-feed of the...
  • Page 44 Important: Do not look directly into the red light of the scanner. e. Contact your engineer or IT support if any of the issues above are not causing the stop. f. If needed, enter correct data at the operator’s station and continue production KVAL DL-NCD Operation/Service Manual 2-18...

  • Page 45: Quick Start Description

    Quick Start Description Quick Start Description Ensure factory air is present at machine and the DL-NCD main air supply valve is turned on. Power up the DL-NCD. See “How to Power Up the DL-NCD” on page 2-21. Home the DL-NCD. See “How to Home the DL-NCD” on page 2-22.
  • Page 46 Quick Start Description Select the file from the Lock Pattern white box. The description of the pattern will dis- play in the blue box below Press the Button to Start Sequence load and run program. KVAL DL-NCD Operation/Service Manual 2-20...

  • Page 47: Powering Up And Down The Dl-Ncd

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

  • Page 48: How To Home The Dl-Ncd

    DL-NCD measures its movement and cutting process. Important: If power is lost or the DL-NCD is reset, the homing routine must be per- formed again to reset the zero reference. Press the button on the touch screen.

  • Page 49: How To Power Down The Dl-Ncd

    Screen will remain on. E-Stop Master Shut OFF The DL-NCD can be a master shutoff for other machines hooked up to the Master Control. For example other machines within the same fenced area will shutdown if the safety gate is opened. or the DL-NCD E-Stop is pressed.

  • Page 50: Description Of User Interface Screens

    DL-NCD. About the Operators Station The operator’s station contains a touch screen to input data and operate the DL-NCD machine. ® The interface is Microsoft Window 7 based.

  • Page 51: Screen Selection Menu Map

    Description of User Interface Screens Screen Selection Menu Map Below are the menu selections for the DL-NCD. “Main Screen” on page 2-24 “Manual Operation” on page 2-33 “Door Width Preset Screen” on page 2-32 “Machine Calibration Screen” on page 2-29 “Diagnostic Screen”...

  • Page 52: Machine Feed Back

    Current Servo Positions • Shows door specifications (located at the right corner). • Shows either Cutout and Lock process being per- formed. Note: Use this information to isolate issues if hav- ing problems with the machine. KVAL DL-NCD Operation/Service Manual 2-26...

  • Page 53: About The Main Screen

    About the Main Screen About the Main Screen The Main Screen is also the startup screen for the DL-NCD. From this screen, all the basic user interface controls are available to run a door. Main Screen FIGURE 2- 19. KVAL DL-NCD Operation/Service Manual...
  • Page 54 Shut Down System down. This must be done before turning power off to the machine. Cut Routine Speed Manually adjust the cutting speeds by pressing the speed percentage but- tons. The new speed will be effective immediately. KVAL DL-NCD Operation/Service Manual 2-28...
  • Page 55 Make sure selected tools match the door type. Tool Type: Displays tool type (Fiberglass, Steel). Tool Status: Displays tool status (Loaded in Cutter, Empty, Disabled) The parameters for each tool are entered in the Machine Calibration Screen. KVAL DL-NCD Operation/Service Manual 2-29...
  • Page 56 This function is a great tool to use if 2 different cutouts are applied to one door. Note: KVAL DL-NCD Operation/Service Manual 2-30...
  • Page 57 The blue boxes will display a description of the tem- Template Description plate selected. To load and run the selected template (s): Ensure all your parameters are correct and the machine is ready to run Press the button. Start Sequence KVAL DL-NCD Operation/Service Manual 2-31...

  • Page 58: About Setup Screens

    Keypad e.If the width needs to be wider, enter a positive number. f. If the width needs to be narrower, enter a negative number. KVAL DL-NCD Operation/Service Manual 2-32...

  • Page 59: About The Machine Calibration Screen

    Click the button to clear any incorrect number in the Offset box, Note: Clear Offset About the Machine Calibration Screen From this screen, you can perform machine calibration. Setup Menu FIGURE 2- 20. KVAL DL-NCD Operation/Service Manual 2-33...
  • Page 60 Check the diameter of the cut and enter measurement and offset data to correct for tool. This adjustment com- pensates for discrepancies to the actual size of the router bit. See “Entering Calibration Data” on page 2-32, for instructions to input data. KVAL DL-NCD Operation/Service Manual 2-34...
  • Page 61 Y-Axis: If the tool needs to move towards the fix fence, enter a negative number. If the tool needs to move towards the adjustable fence, enter a positive number by the amount it needs to move. KVAL DL-NCD Operation/Service Manual 2-35...

  • Page 62: About The Door Width Preset Screen

    Click the adjacent box the in the next column to enter the door width. The results will be displayed on the Main Screen KVAL DL-NCD Operation/Service Manual 2-36...

  • Page 63: About Manual Operation

    About Manual Operation About Manual Operation From this screen, you can control certain functions of the machine in manual mode. Manual Screen FIGURE 2- 21. KVAL DL-NCD Operation/Service Manual 2-37...
  • Page 64 To Forward stop the feed, release the button. • Normal Speed: Press and hold the button to slow speed. To return Normal Speed to previous speed, release the button. KVAL DL-NCD Operation/Service Manual 2-38...
  • Page 65 Sequence • Exit Application: Press the Exit Application button to close the user screen and return to the Windows desktop. This can be used if the operator needs to use a different Windows application. KVAL DL-NCD Operation/Service Manual 2-39...

  • Page 66: About The Diagnostic Screen

    About the Diagnostic Screen About the Diagnostic Screen The Diagnostic screen displays all the tasks the DL-NCD performs. This screen can help with troubleshooting by associating the error code to machine sections or functions. The top line will have the most current routine that is running. This screen also has an indicator to indicate a bad barcode string.This could be a damaged barcode label or coding is incorrect.
  • Page 67 About the Diagnostic Screen KVAL DL-NCD Operation/Service Manual 2-41...

  • Page 68: Chapter 3 System It Administration

    CHAPTER 3 System IT Administration This chapter describes the KVAL DL-NCD controller. The controller is an on board computer that supplies the user interface and controls the operation of the machine. With the controller, KVAL can remotely help troubleshoot your machine.

  • Page 69: About The Dl-Ncd Computer

    Support will be able to access your machine through your company’s Intranet and help solve any issues that may occur. Connection to the Intranet is achieved by interfacing with the DL-NCD controller. The location of the Intranet connection is identified in the figure below (RJ45 to Intranet.)

  • Page 70: Backing Up The Computer

    About Remote Connection to KVAL Service Remote access is a powerful tool to help fix issues that occur with the DL-NCD machine. With the remote access, our KVAL service technician is able to observe your user screen in real time, read, and adjust programming code.

  • Page 71: Updating Door Template Files

    Ethernet connection to transfer files from a remote computer to the machine computer. This section lists some templates provided with the DL-NCD. The templates are text files with the variables located at the top to the file. Below the dotted line is the G-code program. The variables can be changed to match the door’s specifications.

  • Page 72: Generic Rectangle Template (With Round Top Option)

    G Code Variables for Rectangle FIGURE 3- 4. R11,R12 R18=1: Creates a Round Top. Uses same dimensions as the rectangle R18=0: Creates a Standard Rectangle cut Rectangle Variable Dimensions FIGURE 3- 5. KVAL DL-NCD Operation/Service Manual...

  • Page 73: Generic Twin Rectangle Template (With Round Top Option)

    G Code Variables for Twin Rectangle and Twin Rounded Rectangles FIGURE 3- 6. R11,R12 R18=1: Creates a Round Top. Uses same R18=0: Creates a Standard Rectangle cut dimensions as the rectangle Twin Rectangle Variable Dimensions FIGURE 3- 7. KVAL DL-NCD Operation/Service Manual...

  • Page 74: Template For Specials

    Knowledge of drafting programs and programming is recommended for using of this tem- plate. The template below is a sample. Check with engineering or the IT group for your compa- nies template. Update the vari- ables to meet the new template. Cut and Paste Code in this section KVAL DL-NCD Operation/Service Manual...
  • Page 75 Updating Door Template Files Example of Template for Specials FIGURE 3- 8. KVAL DL-NCD Operation/Service Manual...

  • Page 76: Dl-Ncd Barcode Setup

    See Table below. If we have a ''3,3'', this setup counts 3 characters over from the ''0'' Bit. (the 4 character in the string) and pull 3 characters. In the barcode string is ''abcdefg'', it would grab ''def''. If the number pair “0,4” would grab the characters ''abcd'' Bit Number String KVAL DL-NCD Operation/Service Manual...

  • Page 77: Configuration Code Samples

    This section contains samples of the configuration code files. Door Width Start at 0 bit with 2 bit length If XX (Bits 0,1) = 30, Door Width= 35.75'' If XX (Bits 0,1) = 28, Door Width = 31.75'' KVAL DL-NCD Operation/Service Manual 3-10...
  • Page 78 If X (Bit 2) = 8, Door length= 95'' Door Material Start at bit 3 with 1 bit length If X (Bit 3) = L, Door = Steel If X (Bit 3) = R, Door = Wood KVAL DL-NCD Operation/Service Manual 3-11...
  • Page 79 If XXX (Bit 4,5,6) = HR4, (call parameters from Half Light 22x36steal) Door Lock Start at bit 7 with 2 bit length If XX (Bits 7,8) = 1B (call parameters from 2.375BSingle_6-8) If XX (Bits 7,8) = 2B (call parameters from 2.375BDouble_6-8) KVAL DL-NCD Operation/Service Manual 3-12...
  • Page 80 DL-NCD Barcode Setup KVAL DL-NCD Operation/Service Manual 3-13...

  • Page 81: Chapter 4 Maintenance Of The Dl-Ncd

    This chapter describes preventative maintenance steps for KVAL DL-NCD. 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 82: Maintenance Schedule

    Maintenance Schedule Maintenance Schedule KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Refer to this section for steps to perform maintenance. Daily, Monthly, Six Month Maintenance Daily Preventive Maintenance Operation Description Clean Blow off dust from the entire machine.Wipe down the outside of the machine with a clean dry cloth.

  • Page 83: Lubrication Schedule

    Maintenance Schedule Lubrication Schedule KVAL recommends the following lubrication schedule to ensure that the machine operates prop- erly. Recommended Lubrication Schedule TABLE 4-2. Type of Assembly Recommended Schedule Recommended Lubrication Type Linear Bearing Pillow Block Bearing Every 250 Hours of Machine Operation...

  • Page 84: 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. Bearings without grease fittings have been pre-lubricated at the factory and do Note: not require further lubrication.

  • Page 85: 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 86: Adjusting The Air Line Lubricator

    It is recommended to check the lines every week to two weeks. Replace the X-Axis Self Lubricator The DL-NCD contains a self lubricating gear assembly on the X-Axis next to the X-Axis motor. The self-lubricator is electronic and produces nitrogen gas in the well to increase pressure to push the oil out.
  • Page 87 The lubricator kit part number is “Wit Lubricating Kit”. It contains, lubricator well, hose (with oil) and its connectors, bracket, and sensor. Follow the instructions on the next page. Well Hose Sensor Clamp Hose Connectors Wit Lubricating Kit FIGURE 4-5. KVAL DL-NCD Operation/Service Manual...
  • Page 88 After lubricator well is secure on machine, run a test run. Verify the oil is being applied to the gear and there is no alert on the user screen. Close frame and secure wires with a zip tie. KVAL DL-NCD Operation/Service Manual...

  • Page 89: Lubrication Points

    Lubrication Points Lubrication Points This section shows the main lubrication points on the DL-NCD. Frame and Feed Through Cutter Head Points Located on Both Sides of Cutter Head KVAL DL-NCD Operation/Service Manual...
  • Page 90 Lubrication Points KVAL DL-NCD Operation/Service Manual 4-10...

  • Page 91: Chapter 5 Troubleshooting The Dl-Ncd

    Troubleshooting the DL-NCD 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. Chapter 5 at a Glance DL-NCD Sensors ....................

  • Page 92: Dl-Ncd Sensors

    DL-NCD Sensors DL-NCD Sensors On the DL-NCD, sensors provide input to the PLC. The application in the machine is similar to a micro-switch. How Sensors Work On the DL-NCD, 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 93: Locations Of Sensors From The Out-Feed

    DL-NCD Sensors Locations of Sensors from the Out-Feed I-1003 (Tool 4) I-1002 (Tool 3) I-1001 (Tool 2) I-1000 (Tool 1) I-1015 (After Out Feed) Out-Feed Sensor Locations FIGURE 5-1. KVAL DL-NCD Operation/Service Manual...

  • Page 94: Locations Of Sensors From The In-Feed

    Sensors See Figure 5-4 I-1012 (Unsafe to Width Adjust Eye) I-1010 Door Sense I-1011 Eye) (Door Sense Fixed Eye) Movable Dust Hood 24 Volts Blow Off Knock Out Main Pressure OK In-Feed Sensor Locations FIGURE 5-2. KVAL DL-NCD Operation/Service Manual...

  • Page 95: Homing And Limit Sensors

    Z Axis Sensors FIGURE 5-3. I-2002 (X Home) I-2005 I-2004 I-2003 I-2000 I-2001 (Y Limit Home) (Y Limit Neg) (Y Limit Pos) (X Limit Pos) (X Limit Neg) X and Y Axis Homing Sensors. FIGURE 5-4. KVAL DL-NCD Operation/Service Manual...

  • Page 96: Troubleshooting The Air Cylinders

    Check the flow controls to see that they are adjusted correctly and to the proper specifications. Check for any obstructions to the cylinders such as Manual over- ride button screws or a misplaced tool etc. FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS. Check the solenoid air valves: KVAL DL-NCD Operation/Service Manual...

  • Page 97: Adjusting Cylinder Extension Speed

    It might be necessary to call in a specialist or check with KVAL customer service at 1- 800-553-5825. If an Air Leak is coming from an exhaust port on the solenoid air bank: a.Check the solenoid for the manual override.

  • Page 98: 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 99: Troubleshooting With The Status Light Panel

    STEP 4: Stop (Amber) If light is OFF go to item on page 5-12. STEP 5: Start (Amber) If light is OFF go to item on page 5-12. STEP 6: 24VDC (Greening light is OFF go to item on page 5-13. KVAL DL-NCD Operation/Service Manual...
  • Page 100 If no power on the output side, and there is power going into the top of the Control Transformer, replace the Control Transformer. If there is power at the Control Transformer, check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip. KVAL DL-NCD Operation/Service Manual 5-10...
  • Page 101 Troubleshooting Electrical Problems Overload Relay Light OFF The DL-NCD has no overload circuit. There is a wire jumper bypassing the circuit. If light does not turn on, check the jumper for proper connection, E-Stop Light OFF Check to see the if any E-Stop buttons are pulled out....
  • Page 102 Start button and hold it in while a second person checks for voltage between #2 and #5. If there is 110 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wir- ing. KVAL DL-NCD Operation/Service Manual 5-12...
  • Page 103 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-NCD Operation/Service Manual 5-13...
  • Page 104 Troubleshooting Electrical Problems KVAL DL-NCD Operation/Service Manual 5-14...
  • Page 105 2-12 emergency shutdown machine calibration group description 2-23 description 2-34 e-stop light machine feed back description 2-16 user output 2-26 EtherCat® machine feedback smart power supply front section status 2-26 terminals,location KVAL DL-NCD Operation/Service Manual...
  • Page 106 2-4, 5-2 six month voltage levels weekly service manual operation connecting your machine to KVAL Service interface 2-37 service center, contacting information 1-12 menu map 2-25 setup screens 2-32 shut down system overload relay light description...
  • Page 107 Index Windows CE® operating system,about zerk fittings locations zero-energy start-up clean up 1-10 inspect 1-10 KVAL DL-NCD Operation/Service Manual...
  • Page 108 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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