Kval Commander III Manuals

Manuals and User Guides for Kval Commander III. We have 3 Kval Commander III manuals available for free PDF download: Operation Manual, Service Manual

Kval Commander III Operation Manual (168 pages)

Door System With KvalCAM

Brand: Kval | Category: Industrial Equipment | Size: 5 MB

Table of Contents
5
Chapter 1 At a Glance

11
- Introduction to the Commander III
  11
- Overview of the Commander III System
  12
  - Table of Options
    13
  - About this Manual
    15
  - Safety Sheet Sign-Off Sheet
    15
- Safety First
  16
- Zero-Energy to Start-Up
  23
  - Zero-Energy State to Start-Up to Operating State
    23
- Getting Help from KVAL
  25
  - On-Line Help
    26
  - Product Return Procedure
    26
- How to Download the Service Application
  27
  - Download Application
    27
- Safety Sign-Off Sheet
  30
  - A Note to the Operator
    30
Chapter 2 About Kvalcam

33
- Summary of the Kvalcam Interface
  33
  - Machine Line
    33
  - Libraries
    33
  - Machine Control
    34
- About the Libraries
  35
- Controls at the Library Screen
  38
- About Revisions
  44
- About Door Job Creation
  47
- About the Machine Line Screen
  56
  - Machine Line Screen
    56
- About Backing up Data and Checking the Revision Status
  60
- Job Preview Examples
  61
  - Door Face (Lock Preview)
    61
  - Door Edge (Lock Preview)
    62
  - Door Edge (Hinge Preview)
    63
- About Validation
  64
  - About the Validation Screen
    65
  - Outline
    66
- About the Litecutout Feature Detail (DL-NCD Only)
  67
  - Process
    67
  - About the Litecutout Screen
    71
  - About the Work Area Coordinates
    72
  - Sample Oval Cut
    73
- Common Terms
  75
  - Door Job
    75
  - Door Data
    75
  - Feature Group
    76
  - Feature
    77
  - Revision
    77
  - Ad Hoc
    77
  - Variant
    78
  - Diff
    79
  - Axis
    79
  - Validation
    80
  - Validation Report
    80
Chapter 3 Operation of the Commander III

82
- About the Commander III Process
  83
- Summary of Machining a Door
  84
  - Start the Process
    84
  - Load Door Job from Kvalcam
    84
  - Load Door
    85
  - Set-Up Front Section and Machine the Door
    86
- Powering Operations for the Commander III
  87
- About Machine Status Feedback
  90
- About the Commander III Interface Screens
  91
  - Screen Tabs
    91
- About the Main Control Screen
  92
- Machine Controls Section
  93
  - About the Main Control Section
    94
  - About Sequence Control Section
    95
  - About Width Adjust
    95
  - About Carriage Control
    96
  - About Ball Catch
    97
  - About Speed Control
    97
- Machine Feedback and Machine Controls
  98
  - About the Top Feedback Bar
    99
  - About Hinge Tasks Control
    99
  - Hinge Block Descriptives
    100
  - About the Background Colors
    100
  - Shelf Pin Configure and Jamb Stop Section
    101
- About the Manual Servo Control Screen
  103
  - Manual Servo Control
    104
  - Lock Head Movement
    104
  - Outfeed Stop
    104
  - Hinge Carriage
    105
  - Lock Head Movement
    105
- About the Tool Config Tabs
  106
  - Unlock the Tool Slot Configuration
    107
  - About Using Tool Configuration
    107
  - Enable or Disable Tool
    108
  - About Hinge Tool Configuration
    108
  - About Lock Tool Configuration
    109
  - About the Ball Catch Configuration
    112
- About the Tool Path Preview Test Screen
  113
- About the Status Screen
  114
- About the Log Screen
  115
- Calibration of Commander III
  116
Chapter 4 At a Glance

116
- About Calibration
  117
- About the Calibration Tabs
  119
  - Access to the Calibration Adjustments
    119
  - Unlock the Calibration (Option)
    120
- How to Enter Calibration Data
  121
  - About the Calibration Box
    121
  - About Restore Points
    122
  - Enter a Positive or Negative Number
    122
  - Axis Direction for Front Section
    122
  - Axis Direction for Back Section
    123
- Suggested Order of Calibration
  124
  - Start with a Right Hand Door
    124
  - Machine a Left Hand Door
    124
- About the Calibration Screens
  125
  - Summary of Calibrations
    125
  - Opt FC Added Calibrations
    126
  - Summary of Calibrations for Opt FC
    126
  - Hinge Head (over All)
    127
  - Hinge Tools
    128
  - Chisels Calibration
    129
  - Hinge Carriage Location
    130
  - Lock Head
    131
  - Opt FC: Commander III Faceplate and Chisel Calibrations
    133
  - Lock Head General
    133
  - Axis Calibration Direction
    134
  - Plate Router Calibration (Back Section)
    134
  - Chisel Calibration (Back Section)
    135
  - Door Stops
    135
  - Fast and Slow Lock Plate Timing
    136
  - About Lock Plate Timing Calibration
    137
  - Feed System Timing
    137
  - H-Block Display and Jamb Adjustments
    138
  - Door and Jamb Depth Adjustment Mapping
    139
- Special Options (Calibrations)
  141
  - Thickness Feeler Option
    141
  - Thickness Feeler Calibration
    141
  - Process to Calibrate Thickness Feelers
    141
Chapter 5 Tour of the Commander III

143
- Operator's Tour
  143
  - Top View
    143
  - In-Feed Section
    143
  - Front Section
    146
    
    About the Operators Station
    147
  - Hinge Carriage
    148
  - Back Section
    149
  - Option FC: CNC Faceplate and Chisels
    150
  - Out-Feed
    151
- About the Electrical Panels
  152
  - The Main Electrical Panel
    152
  - The High Frequency Panel
    153
- Description of the Six Light Panel
  154
- About Switches and Sensors
  155
- Options
  157
  - Option ND: Narrow Door Fence
    157
- Option W: Lever Lock Drill (Function Drill)
  158
- Option: Thickness Feelers
  159
- Option BC: Ball Catch
  160
- Option SJ: Split Jamb
  161

Kval Commander III Operation Manual (124 pages)

Door System With KvalCAM

Brand: Kval | Category: Industrial Equipment | Size: 5 MB

Table of Contents
5
Chapter 1 At a Glance

11
- Introduction to the Commander III
  11
- Kvalcam and the Commander III
  12
- Overview of the Commander III System
  12
- Standard Features
  12
- Additional Features
  13
- Table of Options
  14
- Bout this Manual
  15
- Operation Manual
  15
- Service Manual
  15
- Kvalcam Reference Manual
  16
- Safety Sheet Sign-Off Sheet
  16
- Safety First
  17
- Safety Guidelines
  17
- Safety Sheet Sign-Off Sheet
  17
- Safety Terminology of Labels
  17
- Follow the P-R-O-P-E-R Lockout Rule of Thumb
  21
- Lockout-Tagout Guidelines
  21
- Lockout Tagout Power
  22
- Lockout Tagout Procedure
  22
- Pre-Steps before Lockout Tagout
  22
- Lockout Tagout Air Supply
  23
- Post Maintenance Steps
  23
- Start Maintenance
  23
- Zero-Energy State to Start-Up to Operating State
  24
- Zero-Energy to Start-Up
  24
- Getting Help from Kval
  26
- Acceptance of Return
  27
- Kval Errors
  27
- Kval Return and Warranty Policy
  27
- Refund Turnaround Time
  27
- Send the Item
  27
- Customer Errors
  28
- Shipper Errors
  28
- Warranty Replacement Parts
  28
- A Note to the Operator
  30
- Safety Sign-Off Sheet
  30
- Operation of the Commander III
  31
- About the Commander III Process
  32
- Load Door Job from Kvalcam
  33
- Start the Process
  33
- Summary of Machining a Door
  33
- Load Door
  34
- Set-Up Front Section and Machine the Door
  35
- How to Power up the Commander III
  36
- Powering Operations for the Commander III
  36
- Home the Commander III
  37
- How to Power down the Commander III
  37
- Emergency Shutdown and Recovery
  38
- About Machine Status Feedback
  39
- Libraries and Machine Line Screens
  40
- Screen Tabs
  40
- Summary of the Kvalcam Interface
  40
- About the Main Control Screen
  41
- Machine Controls Section
  42
- About the Main Control Section
  43
- About Sequence Control Section
  44
- About Width Adjust
  44
- About Carriage Control
  45
- About Ball Catch
  46
- About Speed Control
  46
- Machine Feedback and Machine Controls
  47
- About Hinge Tasks Control
  48
- About the Top Feedback Bar
  48
- About the Background Colors
  49
- Hinge Block Descriptions
  49
- Hinge Section Enable or Disable
  50
- Shelf Pin Configure and Jamb Stop Section
  50
- Jamb Stop
  51
- Jamb Stop Spacers
  51
- About the Manual Servo Control Screen
  53
- Lock Head Movement
  54
- Manual Servo Control
  54
- Hinge Carriage
  55
- Outfeed Stop
  55
- Hinge Head Movement
  56
- About the Tool Config Tabs
  57
- About Using Tool Configuration
  58
- Unlock the Tool Slot Configuration
  58
- Enable or Disable Tool
  59
- About Hinge Tool Configuration
  60
- Tool Config Parameter Definitions
  60
- About Lock Tool Configuration
  62
- Summary of the Lock Tool Config
  62
- About the Lock Edge Bore Config
  63
- About the Lock Edge Plate Config
  63
- About the Face Bore Config
  64
- About the Function Drills Config
  64
- About the Burn Chipout Buttons
  65
- About the Ball Catch Configuration
  66
- About the Tool Path Preview Test Screen
  67
- About the Status Screen
  68
- About the Log Screen
  69
- Calibration of Commander III
  71
Chapter 3 At a Glance

71
- About Calibration
  72
- About the Calibration Menus and the Calibration Reference Cut
  72
- Before You Calibrate
  72
- Flow Chart of Calibration
  73
- About the Calibration Tabs
  74
- Access to the Calibration Adjustments
  74
- Unlock the Calibration (Option)
  75
- About the Calibration Box
  76
- How to Enter Calibration Data
  76
- About Restore Points
  77
- Axis Direction for Front Section
  77
- Enter a Positive or Negative Number
  77
- Axis Direction for Back Section
  78
- Machine a Left Hand Door
  79
- Start with a Right Hand Door
  79
- Suggested Order of Calibration
  79
- About the Calibration Screens
  80
- Summary of Calibrations
  80
- Commander III
  81
- Opt FC Added Calibrations
  81
- Summary of Calibrations for Opt FC
  81
- Hinge Head (over All)
  82
- Hinge Tools
  83
- Chisels Calibration
  84
- Hinge Carriage Location
  86
- Lock Head
  87
- Lock Head General
  88
- Opt FC: Commander III Faceplate and Chisel Calibrations
  88
- Axis Calibration Direction
  89
- Plate Router Calibration (Back Section)
  89
- Chisel Calibration (Back Section)
  90
- Door Stops
  90
- Fast and Slow Lock Plate Timing
  91
- About Lock Plate Timing Calibration
  92
- Feed System Timing
  92
- H-Block Display and Jamb Adjustments
  93
- Door and Jamb Depth Adjustment Mapping
  94
- Process to Calibrate Thickness Feelers
  96
- Special Options (Calibrations)
  96
- Thickness Feeler Calibration
  96
- Thickness Feeler Option
  96
- In-Feed Section
  99
- Operator's Tour
  99
- Top View
  99
- Tour of the Commander III
  99
- Front Section
  102
- About the Operators Station
  103
- Hinge Carriage
  104
- Back Section
  105
- Option FC: CNC Faceplate and Chisels
  106
- Out-Feed
  107
- About the Electrical Panels
  108
- The Main Electrical Panel
  108
- The High Frequency Panel
  109
- About the Nodes
  110
- Typical Block Diagram of Network Connections
  110
- Graphical Sample of Node Connections and Power Distribution
  111
- Description of the Light Tower
  112
- About Switches and Sensors
  113
- Option ND: Narrow Door Fence
  115
- Options
  115
- Option W: Lever Lock Drill (Function Drill)
  116
- Option: Thickness Feelers
  117
- Option BC: Ball Catch
  118
- Option SJ: Split Jamb
  119

Kval Commander III Service Manual (104 pages)

Door System with KvalCam

Brand: Kval | Category: Industrial Equipment | Size: 12 MB

Table of Contents
6
Chapter 1 At a Glance

11
- Introduction to the Commander III
  11
- Overview of the Commander III System
  12
  - Table of Options
    13
  - About this Manual
    15
  - Safety Sheet Sign-Off Sheet
    15
- Safety First
  16
- Zero-Energy to Start-Up
  23
  - Zero-Energy State to Start-Up to Operating State
    23
- Getting Help from KVAL
  25
  - On-Line Help
    26
  - Product Return Procedure
    26
- How to Download the Service Application
  27
  - Download Application
    27
- Safety Sign-Off Sheet
  30
  - A Note to the Operator
    30
  - System IT Administration
    32
Chapter 2 System IT Administration

33
Chapter 3 Maintenance of the Commander III

37
- Maintenance Schedule
  38
- 300 Cycle Maintenance Steps
  40
  - Clean, Clean, Clean
    40
- 600 Cycle Maintenance Steps
  41
- 3,000 Cycle Maintenance Steps
  43
  - Inspect Feed Belts (if Applicable)
    43
  - Inspect All Photo Eyes
    43
  - Inspect Limit Switches
    43
  - Inspect Airlines
    44
  - Refill Lubricators (if Applicable)
    44
  - Grease Ball Screw Bearings
    45
  - Clean Bearing Shafts
    45
- 12,000 Cycle Maintenance Steps
  46
- 72,000 Cycle Maintenance Steps
  48
  - Inspect Nuts and Bolts
    48
  - Check Door Feeding Transition
    48
  - Electrical
    48
  - Computer Backup
    49
  - Wash Filter and Lubricator Bowls
    49
- Maintenance NO-GOES
  50
- Lubrication Schedule
  51
  - Typical Lucubration Kit
    51
- Lubrication Requirements
  52
  - Pillow Block Bearing Housings
    52
  - Flange Bearing Housings
    53
  - Ball Rail Bearing
    53
  - About Taper Bearings
    54
  - Tapered Bearing Housings
    54
  - Ball Screw Nut
    55
  - Ball Screw Drive Assembly
    55
  - Pulley and Idler Shafts
    56
- Sample of Grease Locations for the Machine
  57
  - Front Section Servo Assemblies
    60
- Grease Locations Cutter Head
  61
  - Cutting Head Base
    61
  - Cutting Head Tools
    62
  - Back Section Grease Points
    63
  - Grease Location on the Frame (Feed System)
    64
  - Air Input with Lubrication
    65
  - Air Line Without Lubricator
    66
- Replacing Bits in the Front Section
  67
- Replacing Tooling in the Back Section
  71
- Option W: Replacing Function Drill Assembly
  73
- Collet Torque Values
  74
Chapter 4 Troubleshooting the Commander III

77
- Get Live Technical Help
  77
- About Motion Control
  78
  - Basic Control Circuit
    79
- About a Typical Contactor Control
  80
  - About Contactor Troubleshooting
    81
- About Typical VFD Motor Drive Control
  82
  - About the VFD
    83
  - About VFD Troubleshooting
    84
- About a Typical Pneumatic Circuit
  85
- About Switches and Sensors
  91
  - Using Sensors to Trouble Shoot
    92
- Troubleshooting Electrical Problems
  93
  - If the Power Stops During Normal Operation
    93
- Troubleshooting with the Status Light Panel
  95
  - Control Power Light off
    96
  - Overload Relay Light off
    97
  - E-Stop Light off
    97
  - Stop Light off
    97
  - Start Light off
    98
  - 24VDC Light off
    98
- Network System Overview
  99
  - Connections to Servo Drives
    99
  - Connections to Vfd's (High Freq Panel)
    99

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Kval Commander III Manuals

Kval Commander III Operation Manual (168 pages)

Table of Contents

Chapter 1 At a Glance

Chapter 2 About Kvalcam

Chapter 3 Operation of the Commander III

Chapter 4 At a Glance

Chapter 5 Tour of the Commander III

Kval Commander III Operation Manual (124 pages)

Table of Contents

Chapter 1 At a Glance

Chapter 3 At a Glance

Kval Commander III Service Manual (104 pages)

Table of Contents

Chapter 1 At a Glance

Chapter 2 System IT Administration

Chapter 3 Maintenance of the Commander III

Chapter 4 Troubleshooting the Commander III

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