dl-ncb system reference · the dl-ncb computer-controlled door light cut-out machine is designed to...

Innovation, Quality & Honesty

DL-NCB System Reference

Published: February 27, 2006

p/n: M-DLNCB1 rev 1.0

Proprietary Notice This document contains confidential and trade secret information, which is proprietary to Kval, Inc. (“Kval”), and is protected by laws pertaining to such materials. This document, the information in this document, and all rights thereto are the sole and exclusive property of Kval, are intended for use by customers and employees of Kval, and are not to be copied, used, or disclosed to anyone, in whole or in part, without the express written permission of Kval. For authorization to copy this information, please call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call (707) 762-7367. Copyright © 2006 Kval Incorporated. All rights reserved. KVAL 2006 and DL-NCB are trademarks of Kval, Incorporated.

All other products are trademarks or registered trademarks of their respective holders, all rights reserved. Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated.

Contacting KVAL Customer Service: For further information about this manual or other Kval Incorporated products, contact the Customer Support Department

• http://www.kvalinc.com/customer_service.html (lists all the representatives, including email addresses and phone numbers)

• Mailing address: Customer Support Department Kval Incorporated 825 Petaluma Boulevard South Petaluma, CA 94952

• Phone and Fax: In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485 Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Business hours: Technical Support: 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Friday Parts & Service Sales: 6:30 AM to 4:30 PM Pacific Standard Time, Monday through Friday (Other sales related inquiries: http://www.kvalinc.com/contact_us.html)

• Email: [email protected]

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. What was easy or difficult to use or to learn? If you could change something about the design, what would it be? Please email your comments and suggestions for improvement to [email protected]. (NOTE: This is not a way to get customer support. For that, please refer to the Customer Service contact information above.) Thank you!

This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

Table of Contents ABOUT THIS GUIDE _______________________________________________________________________ I

Audience ............................................................................................................................................................... i How This Guide Is Organized ............................................................................................................................... i Related Publications ............................................................................................................................................. i

Printed Documentation .......................................................................................................................... i DL-NCB Online Documentation Library.................................................................................................ii

CHAPTER 1: INTRODUCTION _____________________________________________________________ 1-1 Overview of the DL-NCB................................................................................................................................... 1-1

Operation Description................................................................................................................................ 1-2 Safety First! ....................................................................................................................................................... 1-2

Safety Guidelines ...................................................................................................................................... 1-2 Lock Out Procedure................................................................................................................................... 1-4

Lock and Tag Out Guidelines ............................................................................................................ 1-5 CHAPTER 2: BASIC OPERATION __________________________________________________________ 2-1

Operator’s Tour ................................................................................................................................................. 2-2 Machine Tour............................................................................................................................................. 2-2

Orientation to Axes and Coordinates................................................................................................. 2-6 KVAL 2006 User Interface......................................................................................................................... 2-7

Launching the KVAL 2006 User Interface .........................................................................................2-7 KVAL 2006 User Interface Visual Tour.............................................................................................. 2-7 Keystroke Shortcuts........................................................................................................................... 2-8 Entering Data ..................................................................................................................................... 2-8

Touch Screen Interface ............................................................................................................................. 2-8 Main Menu ......................................................................................................................................... 2-8 Run Screen ........................................................................................................................................ 2-9 Manual Run Screen ......................................................................................................................... 2-10

Turning the DL-NCB On and Off ..................................................................................................................... 2-11 Powering Up the DL-NCB........................................................................................................................ 2-11 Powering Down the DL-NCB................................................................................................................... 2-12

Emergency Shutdown and Recovery .............................................................................................. 2-13 Homing the DL-NCB ....................................................................................................................................... 2-14 Selecting the Feed Mode ................................................................................................................................ 2-16

Feed Off (Manual Feed) Mode ................................................................................................................ 2-16 Auto-Feed Mode...................................................................................................................................... 2-17 Feed-Thru Mode...................................................................................................................................... 2-17 Reverse Feed Mode ................................................................................................................................ 2-17

Cutting Doors .................................................................................................................................................. 2-18 Creating and Executing a Temporary Door File...................................................................................... 2-19 Running Pre-Defined (Saved) Door Files................................................................................................ 2-21 If There Is Trouble ................................................................................................................................... 2-22 Canceling a Cut ....................................................................................................................................... 2-22

Abort & Restart ................................................................................................................................ 2-22 Override Count................................................................................................................................. 2-22

Restarting a Door File.............................................................................................................................. 2-22 CHAPTER 3: ADVANCED OPERATION ______________________________________________________ 3-1

Advanced Touch Screen Functions .................................................................................................................. 3-2 Main Menu ................................................................................................................................................. 3-2 Run Screen................................................................................................................................................ 3-3 Manual Run Screen................................................................................................................................... 3-4 Tool Changer Screen ................................................................................................................................ 3-5 Machine Data Screen ................................................................................................................................ 3-6

Creating and Saving New Templates ............................................................................................................... 3-6 Creating and Saving a New Rectangle Template ..................................................................................... 3-7 Creating and Saving a New Hole Template ................................................................................................... 3-8 Creating and Saving a New Special Template.......................................................................................... 3-9 Creating a New Template from an Existing Template ............................................................................ 3-10

Modifying (Permanently) an Existing Template .............................................................................................. 3-11


This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

Deleting Templates ......................................................................................................................................... 3-12 Creating and Saving a Permanent Door File.................................................................................................. 3-13

Creating a New Permanent Door File ..................................................................................................... 3-13 Creating a Permanent Door File from an Existing Door File .................................................................. 3-14

Modifying (Permanently) an Existing Door File .............................................................................................. 3-15 Deleting a Door File ........................................................................................................................................ 3-16 Automatic Tool Changer ................................................................................................................................. 3-17

Disabling Tool Holder Locations ............................................................................................................. 3-17 Changing a Tool Manually .............................................................................................................................. 3-18 Changing a Tool Bit ........................................................................................................................................ 3-19 Calibrating the DL-NCB .................................................................................................................................. 3-21

Calibrating the Tool Changer .................................................................................................................. 3-21 Determining Which Calibration Stage to Use.................................................................................. 3-21 Preparing to Calibrate the Tool Changer ........................................................................................ 3-21 Tool Calibration, Stage 1: Calibration Bolt ...................................................................................... 3-23 Tool Calibration, Stage 2: Tool Offset ............................................................................................. 3-27 Tool Calibration, Stage 3: Tool Holders .......................................................................................... 3-31

Calibrating Cut Accuracy......................................................................................................................... 3-33 CHAPTER 4: SYSTEM IT ADMINISTRATION __________________________________________________4-1

System Architecture.......................................................................................................................................... 4-1 Backing up System Files................................................................................................................................... 4-1

CHAPTER 5: MAINTENANCE_______________________________________________________________5-1 Maintenance Schedule ..................................................................................................................................... 5-1

Daily........................................................................................................................................................... 5-1 Weekly....................................................................................................................................................... 5-1 May and December Checkups.................................................................................................................. 5-2

Lubrication Requirements................................................................................................................................. 5-2 Linear Bearings ......................................................................................................................................... 5-2 Flange Bearing and Pillow Blocks............................................................................................................. 5-2 Approved Lubrication Products for Lubricators......................................................................................... 5-2 Gear Motor Lubrication Requirements...................................................................................................... 5-3 Adjusting the Air Line Lubricator (not available on all machines)............................................................. 5-3 Priming the Air Line Lubricator.................................................................................................................. 5-3 Grease Points for Carriage ....................................................................................................................... 5-4

Maintaining the Cutter Motor Spindle ............................................................................................................... 5-6 Preparing the Machine for Spindle Maintenance...................................................................................... 5-6 Checking and Adjusting the Drawbar Extension....................................................................................... 5-7 Cleaning and Lubricating the Spindle Clamping Assembly...................................................................... 5-9

CHAPTER 6: TROUBLESHOOTING _________________________________________________________6-1 Solutions to Common Problems ....................................................................................................................... 6-1 Using the Touch Screen’s Troubleshooting Utility............................................................................................ 6-2

Main Troubleshooting Menu...................................................................................................................... 6-2 Homing Troubleshooting Screens..................................................................................................... 6-3 Plunge Troubleshooting Screen........................................................................................................ 6-5 Auto-Feed Troubleshooting Screen .................................................................................................. 6-6 Servos Troubleshooting Screen........................................................................................................ 6-7 Warning Pop-up Screen .................................................................................................................... 6-8

Using the Touch Screen’s Status Displays....................................................................................................... 6-9 DL-NCB Machine I/O Status Screens....................................................................................................... 6-9

Frame Status Screen......................................................................................................................... 6-9 Carriage Status Screen ................................................................................................................... 6-11

Correcting Cut Accuracy Problems................................................................................................................. 6-12 Troubleshooting the Air Cylinders................................................................................................................... 6-13

Adjusting Cylinder Extension Speed:...................................................................................................... 6-14 Adjusting Cylinder Retraction Speed: ..................................................................................................... 6-14

Troubleshooting Electrical Problems .............................................................................................................. 6-15 If The Power Stops During Normal Operation ........................................................................................ 6-15 Troubleshooting with the Status Light Panel .......................................................................................... 6-16

Adjusting Limit Switches ................................................................................................................................. 6-19 Troubleshooting Photo Detectors ................................................................................................................... 6-20 Getting Help from Kval.................................................................................................................................... 6-21

Product Return Procedure ...................................................................................................................... 6-21 INDEX___________________________________________________________________________________XI

p/n: M-DLNCB1 rev 1.0 February 27, 2006 i This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

About This Guide This guide describes how to operate, maintain and troubleshoot the DL-NCB, a numerically controlled door cut-out system.

Audience This guide is written for machine operators and factory technicians who are responsible for operating and maintaining the DL-NCB machine.

How This Guide Is Organized This guide is organized as follows:

• Chapter 1: “Introduction” Provides a brief introduction to DL-NCB and identifies safety precautions.

• Chapter 2: “Basic Operation” Provides and introduction to the operator features, and provides procedures for accomplishing basic operator tasks.

• Chapter 3: “Advanced Operation” Provides procedures for accomplishing advanced operator and system administration tasks.

• Chapter 4: “System IT Administration” Provides procedures and guidelines for DL-NCB system IT administration.

• Chapter 5: “Maintenance” Describes how to maintain the DL-NCB.

• Chapter 6: “Troubleshooting” Provides problem descriptions and resolutions for troubleshooting the DL-NCB.

Related Publications

Printed Documentation In addition to this System Reference, the following documents are provided with the product (printed) and are also provided in Acrobat PDF format (see DL-NCB Online Documentation Library below).

Document Description Location (in addition to online)

DL-NCB Unpack and Installation Guide (p/n: M-DLNCB2)

Provides guidelines and procedures for site prep, unpacking, positioning, and installing the DL-NCB system

• Top-most item inside the “Open Me First” box, found on the out-feed end of the DL-NCB machine (as shipped)

• System Reference binder Customer Layout Diagram

Diagram showing the DL-NCB and related facility requirements, in context to your facility and manufacturing line

System Reference binder (look for the separate tab for this item)

System Schematics

Complete electrical schematics for the DL-NCB system

System Reference binder (look for the separate tab for this item)


p/n: M-DLNCB1 rev 1.0 February 27, 2006 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

ii

DL-NCB Online Documentation Library Kval provides a library of all system related documentation (including documentation for system components) in Acrobat PDF format. The library can be accessed in the following locations:

• Kval folder on the DL-NCB machine’s computer desktop. Open the folder and double-click on the “Documentation Library” shortcut.

• System resource CD. This CD (labeled “DL-NCB Resource Library”) is tucked into the pocket of the System Reference binder.

• Kval website at http://www.kvalinc.com/support/documentation

p/n: M-DLNCB1 rev 1.0 February 27, 2006 1-1 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

Chapter 1: Introduction This chapter provides a description of the DL-NCB product and identifies safety guidelines that you should follow to ensure safety to personnel and equipment.

Overview of the DL-NCB The DL-NCB computer-controlled door light cut-out machine is designed to rout lock face holes, viewer holes, and lights in doors made of fiberglass, steel or wood.

Notable features of this machine include touch-screen controls, automatic tool selection to match the door material type, automatic door positioning and width adjustment, and a routing cycle that does face boring for locks and cut-outs for door lights.

The spindle is powered by a 3-phase 11-horsepower variable-speed high-frequency motor. A precision tool-holder chuck is mounted on the motor shaft. The on-board computer selects the spindle speed and tooling (from a four-position tool holder) according to the type of door being machined, whether steel, fiberglass or wood, and the type of cut being made.

The standard DL-NCB is configured for residential steel or fiberglass doors, with the capability of machining a wide range of doors ranging from 12-inch wide sidelights to doors that are 4 feet wide by 8 feet high.

All machine programming is done from the DL-NCB operator’s station, which features a touch screen interface that replaces most of the manual switches on the machine. In addition, programming can be done from a personal computer in an office or other remote location by way of an Ethernet connection. By filling in a few data fields in KVAL’s operator interface software, KVAL 2006, only a minute or two is needed to create a program for an entirely new cut-out specification for regular shapes such as rectangles, circular and multiple cuts. KVAL can help with programs to accommodate specialized cuts or machining processes for irregular curves, such as ovals or reversing arcs.

Maximum cut-out sizes are limited to within 3 inches of a door’s top or bottom and to within 1-1/2 inches from the edges of the stiles. Once these shapes have been entered and saved, they may be instantly called up and placed on a “run” list. If created at a remote location, these run lists can be transferred to the machine over a standard Ethernet network.

The DL-NCB may be automated even further by equipping it with optional optical scanning hardware that will read the operation to be done to a specific door from a barcode attached to that particular door unit. KVAL has all the technical expertise needed to help your company’s data processing department develop the interface needed to link your DL-NCB’s barcode reading ability with your company’s existing order entry system.

Standard computer hardware in the DL-NCB includes a Pentium-based CPU running Windows XP. Included are two Ethernet cards, one dedicated to communication with the internal Galil motion controller, and the other available for networking to the rest of your facility and access to the Internet. All DL-NCB installations require that broadband Internet access be provided by the client so KVAL can perform real-time diagnostics and install program updates. Browser access to http://www.kvalinc.com/support is available from the DL-NCB.

On-board diagnostic programs allow the operator to quickly and easily identify the source of any errors and failures, even after they have occurred.



1-2

Operation Description Doors are typically fed from an automatic de-stacker, such as the KVAL Handler or the KVAL ON-3. As the door approaches the DL-NCB’s in-feed zone, sensors detect its width. The in-feed fence may take as much as five seconds to open or close as needed. As the DL-NCB draws the door in, the feed belt shifts to a slower speed just as the door reaches a position registration stop for clamping.

Once clamped, the router plunges into the door and goes through its programmed sequence for cutting lock and light patterns. The routing head reciprocates during the cutting operation to maximize tool life.

After the cutting sequence is finished, the clamps automatically release and the door passes out of the machine through a clean-off tunnel at the out-feed end to remove chips, foam and dust.

Safety First! The DL-NCB is a powerful electro-mechanical motion control system. You should test your motion system for safety under all potential conditions. Failure to do so can result in damage to equipment and/or serious injury to personnel.

Safety Guidelines In addition to the caution and warning labels affixed to the DL-NCB system, follow the guidelines below to help ensure the safety of equipment and personnel.

Guideline Description

Safety Training Insure that all employees who operate this machine are aware of and adhere to all safety precautions posted on the machine and are trained to operate this machine in a safe manner.

Protective Gear Never operate the machine without proper eye and ear protection. Entering the Safety Cage

When changing tools: Opening the safety cage gate will only disable the servo drives and does not disconnect power. This gate is only intended to allow you access to the collets in the tool holder without having to home the machine after. Never reach past the Tool Changer or touch any other part of the machine while power is still on. (See machine diagram on page 2-2.)

When the machine is on: o Never reach hands beyond safety cage. Servo motors can

unexpectedly move quickly and out of control. o Do not clear slugs out of the machine while it is running. o Never perform any maintenance while machine is running. o Never clean the machine while running. o Never walk away from the machine while running.

Compressed Air The compressed air system connected to this machine should have a three-way air valve for shut-off and pressure relief. The air supply providing the pressure to this machine also has a three-way air valve for the supply line. All cylinders on machine are under high pressure and can be very dangerous when activated. Before performing any maintenance or repairs on machine turn the main air disconnect off. Lockout and tag out this connection.

Chapter 1: Introduction


1-3

Guideline Description

Electrical Electrical circuitry on this machine is protected by an approved lockable disconnect circuit. In addition to this equipment, you must install an approved disconnect for the electrical power supplying this machine. This machine is supplied by more than one power supply and is supplied at two different locations. Before performing any repairs or maintenance, lockout and tag out both locations. When opening the cabinet you must first turn off the disconnect switch. When the cabinet door is open there is still power on the top side of the disconnect switch. All maintenance and repairs to electrical circuitry should only be performed by a qualified electrician.

Before Conducting Maintenance

Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tag out, or lock out the electrical and air pressure systems. This should be done in accordance with the state and/or federal code requirements.

Compliance with Codes and Regulations

KVAL Inc. 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 regulations which apply in your geographic area.

Other Hazard Control Action

If you believe any part or operation of this machine is in violation of any health or safety regulation, it is your responsibility to immediately protect your employees against any such hazard and bring the matter to our attention for review and correction, if deemed advisable. Additional detailed safety guidelines are included in the operating instructions of this manual. KVAL will be pleased to review with you any questions you may have regarding the safe operation of this machine.

Still has power in OFF position

3 phase high voltage

110 VAC Power



1-4

Lock Out Procedure

This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991.

Use the following lock-out procedure to secure the DL-NCB while it is powered down. During a lock out, you disconnect all power and shut off the air supply. Be sure to use the tag-out guidelines noted below (page 1-5).

To lock out the DL-NCB

1. Assess the equipment to fully understand all energy sources (multiple electrical supplies, air supply and pressure, spring tension, weight shifts, etc.).

2. Inform all affected personnel of the eminent shutdown, and the duration of the shutdown. 3. Obtain locks, keys, and tags from your employer’s lockout center. 4. Disconnect power (two disconnection locations):

NOTE: Always lock out electrical disconnects on both the large and small electrical cabinets:

a. Turn the disconnect switch on the main electrical panel to the OFF position. Then pull out the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tag-out guidelines below. (see example below)

b. Turn the disconnect switch on the smaller high-frequency panel to the OFF position.

Then pull out the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tag-out guidelines below.

When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided.

Chapter 1: Introduction


1-5

Typical tags

5. Turn the main air valve to the OFF position and place a padlock through the hole (see illustration). NOTE: Place your tag on the padlock, as per the tag-out guidelines below.

6. Once the locks and tags are in place, try to operate the machine to ensure all energy sources are defeated.

7. When maintenance or repairs are completed, the person who performed the work must ensure all tools, spare parts, test equipment, etc., are completely removed and that all guards and safety devices are installed.

8. Before removing the locks and tags, the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re-energized.

9. The locks and tags can then be removed (only by the person[s] who placed them), and the machine can be re-energized.

10. The tags shall be destroyed and the locks and keys returned to the lockout center.

Lock and Tag Out Guidelines • Place a tag on all padlocks. On the tags, include

your name and date. • These locks are only to be removed by the person

on the tag. • If more than one person is working on the

machine, then each additional person places a lock and tag on each disconnect.

• You may only remove your own lock and tag. NOTE: When many people are all working on the same machine you will need a multiple lockout device, such as the one shown here.

• Follow the P-R-O-P-E-R lockout rule of thumb: P ........ Process shutdown R ........ Recognize energy type (electrical, pneumatic, mechanical, etc.) 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 insure they are in the “OFF” state


Chapter 2: Basic Operation This chapter provides the procedures for basic operation of the DL-NCB. (For descriptions and procedures for advanced operator features, refer to Chapter 3, Advanced Operation.)

This chapter contains the following information:

• Operator’s tour: − Machine tour ................................................................................................. 2-2

o Orientation to axes and coordinates .................................................... 2-6 − User Interface tours:

o KVAL 2006 user interface tour .......................................................... 2-7 o Touch Screen interface tour ................................................................ 2-8

• Basic operations: − Turning the machine on and off .................................................................. 2-11 − Homing the DL-NCB .................................................................................. 2-14 − Selecting the feed mode .............................................................................. 2-16 − Cutting doors:

o Overview .......................................................................................... 2-18 o Creating and executing a temporary door file .................................. 2-19 o Running pre-defined door files ......................................................... 2-21 o Canceling a cut in progress ............................................................... 2-22 o Restarting a door file ........................................................................ 2-22

Before operating the DL-NCB, be sure to review the safety guidelines provided on page 1-2.



2-2

Operator’s Tour This section provides an overview of the features of the machine most frequently used by operators (for example: status lights, operator interface, Touchscreen interface). For advanced operator features, refer to Chapter 3, Advanced Operation.

Machine Tour

(See machine item descriptions below)

Rear Access Gate

E-Stop Switch (could be another next to Tool Access Gate)

Call Door Foot Pedal

Manual Reverse Feed & Width

Adjust Buttons

Out-Feed end of machine

Drive Reset Buttons

In-Feed end of machine

Fixed Fence

Adjustable Fence

Cutter Gantry

Tool Changer

Tool Changer Access Gate

Operator’s Station • Touchscreen • Operator Panel • Computer, Monitor • Status Light Panel

Chapter 2: Basic Operation


2-3

Machine Item Descriptions:

• Cutter Gantry and Tool Changer:

(view from In-Feed side of machine)

Cutter Gantry: Comprises the part of the machine that moves the Cutter Head into position to make cuts on the door. It has an X carriage that moves up and down the length of the machine (along the X axis) carrying the Y carriage which traverses the width of the door (Y axis) and has the Cutter Head attached to it. Tool Changer: The Tool Changer holds up to four Tools, each in it’s respective Tool Holder. During normal operation, the machine automatically moves to the Tool Changer to exchange tools, ensuring it has the tool appropriate to the type of door being cut (steel or fiberglass). For more information about the Tool Changer, see page 3-17. Tool: Comprises the cutter bit (either a single flute pointed cutter for steel or a double fluted carbide cutter for wood or fiberglass) and the Collet Assembly that holds the bit. (See illustration at left.) Collet Assembly: Considered part of the “Tool,” it holds the bit (secured with a special nut). The top of the Collet Assembly is the part that allows the tool to be held securely in the Tool Holder (on the Tool Changer arm) and in the Cutter Head.

Tool Changer

Tools (in Tool Holders)

Tool (in Cutter Motor)

Cutter Head

Cutter Gantry

Bit

Collet Assembly

Tool



2-4

• E-Stop Switch: This switch is to be used when the machine is out of control or is about to damage personnel or equipment. See page 2-13 for details.

• Rear Access Gate: Provides access to the bearing and servo motors on the back of the machine.

Opening this gate has the same effect as activating an E-Stop.

• Tool Changer Access Gate: Provides access to the Tool Changer, Cutter Head (for changing tools), and other items at the in-feed side of the machine.

Opening this gate disables the drives and prevents the machine from moving..

• Drive Reset Buttons:(Located on front of High-Frequency Cabinet)

If one of these buttons is lit, it indicates that the respective motor drive (Cutter, Feed or Width-Adjust) has a fault. For further fault analysis, a fault code is displayed on the drive, located inside the high-frequency cabinet. To reset the drive, press the button.

• Start Reverse Feed Sequence and manual Width Adjust buttons: These buttons are for use while operating the machine in Reverse Feed Mode (see page 2-17 for details)

• Call Door Foot Pedal: Use the pedal to manually advance the door in the machine (see page 2-17 for details).

E-Stop Functionality

When an E-Stop switch is activated, cutting stops, the door is unclamped, all motors deactivate, and all I/O power is killed. Only the computer and Galil motion controller remain powered.

The machine responds in the same way if you:

• Press the STOP button on the operator’s station.

• Open the Access Gate closest to the E-Stop Switch.



2-5

• Operator’s Station:

− Monitor (computer): Use for running KVAL 2006 software (see page 2-7), accessing

other system resources in the KVAL folder on the desktop, and accessing the network and Internet.

− Control Panel buttons/switches: o Control Transformer button: Controls power to control circuits and computer.

Push in to kill power to machine, pull out to restore power (see pages 2-11 and 2-12 for related power up and power down procedures).

o Machine Start and Stop buttons: Controls power to the machine, with the exception of the computer and control circuits. The Control Transformer button must be ON (pulled out) for these buttons to function.

o Reset Drives button: Resets X-axis and Y-axis servo motor drives. o Speed Select switch: Selects cutting speed (only affects speed when the cutter is

down). o Disable Auto Feed button: When ON, it disables the Auto-Feed mode. Motors

are still enabled for manual control. − Touchscreen:

o Basic Operation Screens: see page 2-8. o Advanced Operation Screens: see page 3-2. o Troubleshooting Screens: see page 6-2. o Machine and I/O Status Screens: see page 6-9.

− Status Light Panel. All lights are illuminated on successful power-up. See page 6-16 for how to use these status lights for electrical troubleshooting.

− NOTE: The work surface (under the keyboard and mouse) lifts up to provide storage for manuals and other items.

Monitor (shows KVAL 2006

Interface)

Control Panel

Touch Screen

Status Light Panel



2-6

Orientation to Axes and Coordinates

Item Descriptions:

• Home: The corner of the machine (out-feed end of the fixed fence) that the Cutter Head travels to during the homing operation. All measurements are referenced from this point (home position is X:0.000, Y:0.000). For details on homing, refer to page 2-14.

• X Axis: Travel along the length of the door. • Y Axis: Travel across the width of the door. • Positioning coordinates (+ and –): Most cut parameters that you enter in the KVAL 2006

interface are relative to the following convention: − X axis:

Positive (+) direction is toward the out-feed end of the machine. Negative (–) direction is toward the in-feed end of the machine.

− Y axis: Positive (+) direction is toward the fixed fence. Negative (–) direction is toward the adjustable fence.

• Primary Stop: The door stop on the out-feed end of the machine. This stop is usually used for Left Hand doors. (A Left Hand door is a door that is fed into the machine top first).

• Secondary Stop: The door stop on the in-feed end of the machine. This stop is usually used for Right Hand doors. (A Right Hand door is a door that is fed into the machine bottom first).

• Fixed Fence: This is the non-movable fence that the edge of the door clamps against. • Adjustable Fence: This is the movable fence (opposite the Fixed Fence) that the edge of the

door clamps against. It slides back and forth to adjust to the size of the door. • In-feed end of machine: This is the end of the machine near the Tool Changer. Typically doors

are feed into the DL-NCB at this end from a door de-stacking machine, such as the ON-3. • Out-feed end of machine: This is the end of the machine nearest the Operator’s Station.

Typically, doors are moved out this end to the next part of the door processing line. You can feed a door into the machine from this end if the Reverse Feed mode is selected via the Touchscreen (see page 2-17 for details).

–

+ –+

X Axis

Secondary Stop

Fixed Fence

Primary Stop

In-Feed end

Adjustable Fence

Y Axis

Out-Feed end

Home Location

Right-hand door

View of machine without Cutter Gantry



2-7

KVAL 2006 User Interface You use the KVAL 2006 software program, in conjunction with the Touch Screen menus, to control the DL-NCB.

Use the KVAL 2006 software to define and execute door files, which contain the specifications for the cuts the DL-NCB makes on the doors. (Note: The unit of measure for all door specifications is inches.)

Use the Touch Screen menus to manually control the DL-NCB’s mechanical operations and movement, select operation modes, and conduct troubleshooting and maintenance functions. For details on the Touch Screen menus, see page 2-8.

Launching the KVAL 2006 User Interface On the Operator’s Station computer, the KVAL 2006 user interface, in addition to other system administration software, has a shortcut on the desktop in a folder called “KVAL.” To launch the KVAL 2006 user interface, open the KVAL folder and double-click the KVAL2006.EXE shortcut.

KVAL 2006 User Interface Visual Tour Following is a general overview of the KVAL 2006 user interface functions. Details about the various interface elements are provided in context to the procedures for homing the machine (see page 2-14) and cutting doors (see pages 2-18 through 2-22).

Displays the specs for a selected door, or for a selected cut.

This area displays the cuts to be made on the door.

Click this button to download the selected door file. The cutting commences after the door is clamped into the machine.

Displays either: o Door files that can be

downloaded & run. o Cut templates that can

be assigned to a door file.

o List of templates as assigned to a specific door file.

These buttons are used while defining or modifying door files or cut templates.

These buttons are used to cancel a cut in process. See page 2-22 for details.

Displays the real-time X-Y-Z location of the cutter head.

“Width” displays the width of the door presently clamped into the machine (measured by the machine).

To Home the machine, click “Maint” once, then click the button below it (“Home”). See page 2-14 for details.

To enter Calibration mode (see page 3-21) click “Maint” twice.

Click this button to finish processing the current door, but clear all subsequent door files. See page 2-22 for details.



2-8

Keystroke Shortcuts Keystroke Shortcut Description

F1 Stops the downloaded door file from being executed by the DL-NCB. F2 After pressing F1, you can then use the F2 key to clear the downloaded

door file from the DL-NCB and make it ready to receive another door file.

F5 Creates a temporary door file. This is a quick way to enter door parameters before cutting the door. This is an alternative to using a saved (permanent) door file, or using a barcode.

F8 Downloads the loaded door information to the DL-NCB. The machine will run as soon as the door clamp is engaged.

Entering Data When entering data for a door or template, enter the data in the respective field and press the Enter key to proceed to the next field.

All measurements are in units of inches.

TIP: When entering values, you can type in fractions and let the software calculate the decimal equivalent. For example, if you type “35 7/8” (place a space between “35” and 7/8”) into a parameter field and press the Enter key, the software automatically converts the value to 35.875 inches.

Touch Screen Interface The following is an overview of the touch screen functions for basic machine operation.

For details on other touch screen functions, see:

• Advanced operation screens (see page 3-2) • Troubleshooting screens (see page 6-2) • Status Display screens (see page 6-9)

Main Menu

See Run screen description below (page 2-9)

See Manual Run screen description below (page 2-10)



2-9

Run Screen

Button or Group Description

FEED (group) Use these buttons to select the Feed Mode (see page 2-16 for details): • Feed Off: Selects Manual Feed Mode, where you manually feed in and clamp

the door (see Manual Run screen on page 2-10). Note: This is the power-up default (other selections are not retained after cycling power.)

• Auto Feed: The door is automatically fed in, clamped in the appropriate location, cut per the information from the downloaded door file, and fed out to the next machine or assembly table when it is ready.

• Feed Thru: Doors are not processed by the DL-NCB. Rather, they are fed from the in-feed end of the machine to the out-feed end, without clamping and cutting.

• Rev Feed: Like Auto Feed, but doors are fed in from the out-feed end of the machine.

SELECT TOOL (group)

These two buttons select which tool is used for cutting steel or fiberglass doors. For example, if the buttons read Steel #1 and Fiberglass #4, tool #1 will be used for cutting a steel door and tool #4 will be used for cutting a fiberglass door.

Disable Tools Opens a pop-up, where you can turn off any of the four tools. If a tool is disabled (OFF), the changer will not attempt to use it, and it’s icon will show as red. Refer also the Disabling Tool Holder Locations procedure on page 3-17.

Motor Warm-up Displays the % complete of the warm-up cycle. This reads 100% when the warm-up cycle is complete.

Eject 1 Manually turns on/off the Eject function. When the Eject function is on, the cutout slug is physically knocked out with a air cylinder after the cut is complete.

Oscillate Manually turns on/off bit oscillation. When on, the cutting tool reciprocates, increasing bit life. NOTE: As shipped from the factory, the DL-NCB allows oscillation on all 4 tools. However, this touchscreen setting will have no effect if you set the tool’s Oscillate value to zero in Calibration Page 2 of the KVAL 2006 interface. (See page 3-34 for instructions to access calibration pages.)

Security Lock Manually turn on/off Security Lock Mode. When on, the tool does not plunge all the way through the door.

Download Received

Indicates if the DL-NCB has a door file downloaded to it and is available to be run.

MENU Return to Main Menu (see page 2-8)

Tool Changer Go to Tool Changer menu (see page 3-5)

Manual Run Go to Manual Run menu (see page 2-10)

Pop-up



2-10

Manual Run Screen


Auto Adjust Enable or disable auto-adjust feature. If enabled, the fence width adjusts to the size of the incoming door. If disabled, no door width adjustment is made. It retains its state after power is turned off.

Auto Feed Enable or disable auto-feed feature. If enabled, the auto-feed system operates normally (see page 2-17 for details). If disabled, the feed system must be operated manually.

Setup Turn on/off setup mode. While in setup mode, the machine goes through all operations as it would normally, but the cutter does not plunge in to cut the door. It is used to test new templates before actually cutting a door.

Feed (speed) Manually puts the feed speed into slow. This is used for manually positioning the door in locations other then one of the two stops.

Open, Close Use these buttons to manually open or close the adjustable fence to accommodate doors of different sizes.

FWD, REV Use these buttons to manually position the door. FWD jogs the door forward (toward the out-feed end), REV jogs the door in reverse. The feed moves as long as the button is being pressed.

Clamp Use this button to manually clamp and unclamp the door.

Stop Use this button to manually raise and lower the door stop. The left-hand stop (Primary Stop) will be used when a left-hand (LH) door is downloaded. The right-hand stop (Secondary Stop) will be used when a right-hand (RH) door is downloaded.

Download Received Indicates if the DL-NCB has a door file downloaded to it and is available to be run.


DLNCB I/O Status Go to DL-NCB I/O Status screens (see page 6-9)


Run Menu Go to Run menu (see page 2-9)



2-11

Main Switch Panel

Turning the DL-NCB On and Off Use the procedures below for powering up and powering down the DL-NCB.

Notes:

• The DL-NCB retains, in memory, the tool it had at the time it was shut down. If you change the tool while the machine is off, just make sure that the only empty tool slot that is not disabled is for the tool in the Cutter Head. For details on how to disable tool holder locations via the Touchscreen interface, refer to Disabling Tool Holder Locations on page 3-17.

• After the DL-NCB has been shut down for more than 15 minutes, the motor requires 10 minutes to warm up. The machine can be shut off for up to 15 minutes without having to let it warm up. This allows you to inspect the machine or change tooling with minimal down time on the manufacturing line.

Powering Up the DL-NCB Powering up the system includes: • Applying power to the entire system • Starting the Control Circuit • Logging on to the Operator’s Station

To Power Up the DL-NCB

1. Make sure the electrical disconnects on both the main and secondary electrical cabinets (see page 1-4) are turned to the ON position.

2. Pull out the CONTROL TRANSFORMER switch. It should light up.

− The computer should start up and the computer monitor should turn on.

3. Push the START button. − All lights on the Status Light Panel should be illuminated.

CONTROL POWER

OVERLOAD RELAY

E-STOP

STOP

START

24VDC

4. Launch the KVAL 2006 user interface:

a. Open the KVAL folder on the computer desktop. b. Double-click the KVAL2006.EXE shortcut. The KVAL 2006 user interface opens (see

example below).



2-12

5. The DL-NCB is now ready for the next steps to prepare for system readiness – this includes:

a. Execute the Homing operation from the KVAL 2006 interface (see details about homing on page 2-14).

b. Select the Feed Mode from the Touchscreen panel (see details about Feed Modes on page 2-16). By default (power-up state), the DL-NCB is in Manual Feed mode (Feed Off).

Powering Down the DL-NCB Powering down the system includes: • Shutting down the computer. • Shutting down the control power. • Removing power from the entire system

To Power Down the DL-NCB

1. On the computer: a. Close all open applications. b. Shut down the computer: Click the “Start” button in the bottom left corner of the

screen. In the Shut Down dialog, select “Shutdown” and then click the “OK” button.

When the computer screen goes blank, it is OK to proceed to the next step.

2. Push in the CONTROL TRANSFORMER switch. This kills power to the machine. All status lights should be off.

3. Kval also recommends that you turn the disconnect switches on both electrical cabinets to OFF; this helps reduce possible damage resulting from power surges from electrical storms.



2-13

Emergency Shutdown and Recovery There is an emergency shutdown (E-Stop) switch located on the DL-NCB safety cage next to the access gate by the large electrical cabinet (see illustration below) and/or located near the Tool Changer access gate. This switch is to be used when the machine is out of control or is about to damage personnel or equipment.

When an E-Stop switch is activated, cutting stops, the door is unclamped, all motors deactivate, and all I/O power is killed. Only the computer and Galil motion controller remain powered.

NOTE: The machine responds in the same way if you: • Press the STOP button on the operator’s station. • Open the Access Gate closest to the E-Stop Switch.

To Resume Normal Operation after an E-Stop

If an E-Stop is activated, use the following procedure to recover, after the cause of the emergency stop is resolved:

1. Pull the E-Stop switch back out to deactivate it. 2. Push the START button on the operator’s station. 3. Home the DL-NCB (see instructions on page 2-14).

After this, the machine should be ready for normal operation.

Close-up of E-Stop Switch



2-14

Homing the DL-NCB DL-NCB must go through a homing routing before any other operation is performed. Performing the homing routine establishes a home position – a zero-reference position from which the DL-NCB measures its motion when making cuts and when moving to the Tool Changer.

You should home the DL-NCB:

• After powering up the system (see page 2-11) • After hitting the STOP then START buttons • When recovering from an Emergency Stop (see page 2-13)

To Home the DL-NCB

1. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the

blank button below it to read Home.

↓

↓

2. Click twice on the Home button. The DL-NCB should start the homing operation.

NOTE: While the homing operation is in progress, the Home button changes its label to Homing. If there is no movement, check the Troubleshoot Homing touchscreen (see page 6-3).

Homing Operation Sequence of Events:

a. When the DL-NCB is commanded to home, it moves the Cutter Head to the home position (position is X:0.000, Y:0.000). The home position is at the out-feed end of the fixed fence, as illustrated in the following photo.

Cutter Head at Home Position

Fixed Fence

Tool Changer

Calibration Bolt



2-15

b. After finding the home position, the DL-NCB automatically moves the Cutter Head to the Tool Changer location and makes sure the Calibration Eye aligns with the Calibration Bolt.

c. Once the machine has verified that the eye is aligned with the bolt, it moves the eye to scan all four tool positions, and records which ones are holding tools.

Note: The DL-NCB will not scan the tools if all tool positions are disabled via the Touchscreen (see page 3-17 for instruction on disabling tool positions).

d. After scanning all four tool locations, the machine moves the cutter head to the Ready for Work position (X:54.999, Y:14.999).

e. In addition to moving to the Ready for Work position, you can tell the homing operation was successful by noting the button in the bottom right corner of the KVAL 2006 interface changes its label to PROGRAMS LOADED.

Correct alignment of

Eye over Bolt

Calibration Eye

Calibration Bolt

Scan Path for Photo Eye



2-16

Selecting the Feed Mode

You can operate the DL-CB in one of four different feed modes. Each mode is selected in the Run Screen menu of the Touchscreen.

• Feed Off (Manual Feed) Mode

• Auto-Feed Mode • Feed-Through Mode • Reverse-Feed Mode By default (power-up state), the DL-NCB is in Manual Feed mode (Feed Off). The feed mode selection is not retained when you cycle power to the machine.

To access the Run screen, press the Run or Run Menu button from any of the following screens: Main Menu screen Manual Run screen Machine Data screen

Run screen

The feed mode can be changed at any point, but is best to be done while there is no door in the machine.

The following sections describe each mode in greater detail.

Feed Off (Manual Feed) Mode Manual Feed mode allows you to do all feed and clamp operations manually. The operator manually feeds in and positions the door using the FWD and REV buttons on the Touchscreen. The stop can manually be raised and lowered using the Stop button on the

Touchscreen. Finally, the Clamp button on the Touchscreen clamps the door at it’s current position. If a door file has been downloaded, the machine will start cutting the door after the door is clamped; otherwise, it will wait until it receives a downloaded door file.

NOTE: When the DL-NCB is powered up, it is automatically set to Manual Feed (Feed Off) mode.

To position and clamp the door in Manual Feed Mode: In the main menu, press the Manual

Run button to access the Manual Run screen.

Use the Open and Close buttons to adjust the fence width for the given door.

Once the fence is correct, use FWD and REV to feed the door into position.

Press the Stop button to raise the door stop. (Use the REV button to bring the door back to the stop if the in-feed stop is used.)

Press the Clamp button. After the machine clamps the door, it runs the downloaded door file.



2-17

Auto-Feed Mode Auto-Feed mode is the normal mode of operation. The door is automatically fed in, clamped in the appropriate location, cut per the information from the downloaded door file, and fed out to the next machine or assembly table when it is ready.

Feed-Thru Mode Feed-Thru mode is used when the DL-NCB is to be un-used but doors need to be fed through it. In this mode, doors are fed from the in-feed end of the machine to the out-feed end, without clamping and cutting.

“Null” Option: While running in Feed Off or Auto-Feed mode, you can run one or more doors through the machine without making any cuts. To do this, when you create the door file (see page 2-19) type “null” in the Cutout #1 field, instead of using a regular cut template.

When the door file is downloaded and run, the door will still stop in the DL-NCB to be clamped; then the door will be released and fed out without making any cuts. Thus, we recommend the Null method when passing through one or a few doors, but use the Feed-Thru mode when passing many doors through the DL-NCB to the next stage of the door processing line.

Reverse Feed Mode Reverse Feed mode is similar to Auto-Feed mode, but rather then feeding the next door from the front of the machine; the door is fed in from the out-feed end. This allows you to process doors from either end of the machine.

To Reverse Feed a Door

1. Change the feed mode to Feed Reverse on the touch screen. 2. Make the door width adjustment. Use the OPEN and CLOSE

buttons located on the safety fence near the out-feed end of the machine. Door width plus ¼ inch is good rule of thumb.

3. Back the door in so that the photo eyes are covered and about 12 inches of the door is on the orange feed belt.

4. Press the START REVERSE FEED SEQUENCE button (located next to the OPEN/CLOSE buttons on the safety fence).

5. After the door cutout program runs and the door is unclamped, press and hold the Call Door foot pedal to feed the door completely out of the machine.

Note: Failure to get the door out completely and away from the path of the photo eyes may cause the door to go back into the machine again. If this happens, quickly press the foot pedal to feed it back out. If the door is reclamped before you press the foot pedal, go to the Touchscreen and navigate to the Manual Run screen and press the Clamp button, and then press the foot pedal to out-feed the door.

6. After the first reverse-feed door, all that is required to run subsequent doors is to push them in past the photo eyes.

7. Be certain to go back to the touchscreen and turn Reverse Feed off prior to resuming Auto Feed. Also, visually check that the in-feed stop is retracted prior to resuming Auto Feed.



2-18

Cutting Doors When the DL-NCB cuts a door, it is executing a door file. The door file contains specifications for the door and the cuts to be made. Each cut (rectangle, hole, or special) is derived from a predefined template and can be run as is, or temporarily modified for the door file being executed. You have three basic options for executing door files:

Create and execute a temporary door file: You enter the parameters for the door and the cuts, and then click the Down Load button. The door file is not saved, but may be used for multiple doors. Use this method for non-standard doors or if you simply don’t have a saved door file for that particular door. For detailed instructions, see page 2-19.

Execute a saved door file: You simply select the saved door file from the Door List and click the Down Load button. For detailed instruct-ions, see page 2-21.

Scan a barcode: To do this, you must first create a saved door file and associate a barcode value to that door. When the barcode is scanned, it automatically loads the associated door file and executes it to make the appropriate cut(s) on the door. Contact Kval Customer Service for help setting up barcode scanning operations.

Run

Yes

No

Modify cut template

parameters?

Change the door width (if needed)

Select the door material

(if needed)

Select cut templates

(as needed)

Enter the # of doors to cut (LH or RH).

Download

Modify the cut templates

(templates are not permanently

changed)

Press the F5 Key

Select a door from the

“Door List”

Scan a Barcode

Option Overviews

Option Flowcharts



2-19

Creating and Executing a Temporary Door File To cut non-standard doors or if you simply don’t have a saved door file for that particular door, you can create a temporary door file. The door file contains the specifications for the door and the cuts to be made. Each cut (rectangle, hole, or special) is derived from a template.

In this temporary door file, you provide the parameters for the door specs and the cuts to be made. The file may be used on multiple successive doors. Therefore, the temporary door file is created and executed in one process as described below.

To Create and Execute a Temporary Door File

1. Press the F5 key. This clears the previous door and allows you to enter data for a new door.

(NOTE: If at any point you wish to restart this process, press the F5 key.)

2. Enter parameters for the new door. Remember to press the Enter key to ensure the parameters you type in are saved in the file. The following describes how to enter most parameters potentially used in a door file (typically, you will only have to enter some of the parameters for a given door):

a. Door Width: Type in the width (if different from the default setting).

b. Door material: Click the button or press F12 to toggle between Steel and Fiberglass: or .

CAUTION: Be sure to select the correct door material. If you select the wrong door material, the DL-NCB will use the wrong cutting tool to cut the door and will likely damage the door, the cutting tool and other DL-NCB equipment.

c. Cutout: For the “Cutout” field, type the name of the template you want to add to the door. If the typed template is not in the template list, it will not let you continue. Instead of typing the template name in the Cutout field, you can find the item in the Template List, click once on it, and press the Enter key to apply it to the parameter field.

Note: To add additional cutouts on the same door, click on the Cutout # field and use the <Shift>+Arrow Up key combination to increment to the Cutout #2 parameter and enter the name of the template. Up to 30 cutouts can be added to a door. To navigate back to Cutout #1, use the <Shift>+Arrow Down key combination.

d. Lock #: Enter the lock template name from the Template List. e. (Lock Backset: Let the Lock Backset value be auto-filled based on the template selected

for Lock #. Just press the Enter key to move to the Deadbolt # parameter.) f. Deadbolt #: Enter the lock template name from the Template List. If it is auto-filled



2-20

based on the template selected for Lock #, just press the Enter key to move to the Centers parameter.

g. (Centers: Let the Centers value be auto-filled based on the specifications from the selected Deadbolt #. Just press the Enter key to move to the LH parameter.)

h. LH or RH: Enter the number of left-hand doors (feed top first) or right-hand doors (feed bottom first) to process with the presently selected door file parameters.

Note: If you are running the door file on LH and RH doors, use the following sub-procedure to select which door type to process first. 1. Click the Edit Off button until the button name changes to Edit On

and flashes. 2. Click this button until the desired feed order (“RH First” or “LH

First”) is shown on the button. The click order cycle is: …

3. Click the Edit On button until the button name changes to Edit Off and stops flashing.

3. (OPTIONAL) Modifying Template Parameters: After typing the LH or RH value and pressing Enter, the “Template List” is replaced by the “Door Item List” and displays the templates used in this door file. Use the following procedure to modify the cut parameters:

Note: Template parameters are changed only for the temporary door file and are not permanently changed):

a. Click once on the parameter from the “Door Item List.” This displays the parameter details for the template. (The example shows the parameters for cut template 045.)

b. Make any necessary changes to the template parameters. For detailed information on template parameters see page 3-6.

c. Repeat steps 3.a. & 3.b. for other cut template parameters you need to modify for this door.

4. Click the Down Load button or press the F8 key to download the door file to the DL-NCB.

As soon as the DL-NCB is ready (door is fed into machine and clamped), it will execute the door file and make the associated cuts on the door. If you are running the machine in Manual Feed mode, see page 2-16 for how to feed in and clamp the door.

Note: If you need to cancel a door cut in progress, refer to the instructions on page 2-22.

The selected template is identified with a diagonal line, like this.



2-21

Running Pre-Defined (Saved) Door Files Use the following procedure to cut doors using pre-defined (saved) door files. For instructions on creating saved door files, refer to page 3-13.

To Cut a Door Using a Saved Door File

1. Make sure the DL-NCB has been homed (see page 2-14 for instructions).

2. Click the List Title until it reads “Door List.” 3. Locate the desired door in the Door List and double-click on it.

Tip: If the door list is long, instead of scrolling to search for the door, you can start typing the name of the door in the Door List field above. The list automatically scrolls to the closest matching text string.

4. (OPTIONAL) Modifying Template Parameters: Use the following procedure to modify the cut parameters:

Note: Template parameters are changed only for the temporary door file and are not permanently changed):

a. Click once on the parameter from the “Door Item List.” This displays the parameter details for the template. (The example shows the parameters for cut template 045.)

b. Make any necessary changes to the template parameters. For detailed information on template parameters see page 3-6.

c. Repeat steps 4.a. & 4.b. for other cut template parameters you need to modify for this door.

5. Click the Down Load button or press the F8 key to download the door file to the DL-NCB.

As soon as the DL-NCB is ready (door is fed into machine and clamped), it will execute the door file and make the associated cuts on the door. If you are running the machine in Manual Feed mode, see page 2-16 for how to feed in and clamp the door. When the door cut is complete, the DL-NCB positions the Door Plunger over the center of the cut and knocks the cut piece to the rollers below, where you can pull out the scrape pieces.

The selected template is identified with a diagonal line, like this.



2-22

If There Is Trouble If there is a problem with the KVAL 2006 software, click on the Exit button and wait until the program stops. Then restart the software.

If the machine is in an unknown state, first turn the machine off, then wait 20 seconds, then turn the machine on. Refer to the instructions for powering the system on and off (beginning on page 2-11).

Canceling a Cut There are two methods for canceling a cut. The following description outlines when to use one or the other.

Abort & Restart

An Abort & Restart halts any movement from the DL-NCB, unclamps the door (if clamped), and clears out both current and pending downloads. The machine is left in a clear and ready state.

To initiate an Abort & Restart, press the ABORT button (or press the F1 key) and then the Restart button (or press the F2 key). The DL-NCB will indicate a successful restart by moving a short way up and back on the X axis.

Override Count Unlike the Abort & Restart, an Override Count operation does not stop any current operation. If the cut has not yet started, it will clear out the downloaded door and make the machine ready for a new download. If the

DL-NCB is in the middle of a cut, it does not halt the current cut. It clears any quantity left for the current download and makes the machine ready for a new download.

To initiate an Override Count, press the Override Count button.

Restarting a Door File You can return to the last door file that was downloaded by pressing the Return to Downloaded Door button.

From this point you can download the door again, or modify it before downloading it.


Chapter 3: Advanced Operation This chapter provides the advanced procedures for operating the DL-NCB (for basic operation, refer to Chapter 2).

This chapter contains the following information:

• Advanced touch screen functions .............................................................................. 3-2 • Creating and saving new templates ............................................................................ 3-6 • Modifying (permanently) an existing template ........................................................ 3-10 • Deleting templates ................................................................................................... 3-12 • Creating and saving a permanent door file .............................................................. 3-13 • Modifying (permanently) an existing door file ........................................................ 3-15 • Deleting a door file .................................................................................................. 3-16 • Automatic Tool Changer overview .......................................................................... 3-17 • Disabling tool holder locations ..................................................................................3-17 • Changing a tool manually ........................................................................................ 3-18 • Changing a tool bit ................................................................................................... 3-19 • Calibrating the Tool Changer .................................................................................. 3-21 • Calibrating cut accuracy .......................................................................................... 3-33

Before operating the DL-NCB, be sure to review the safety guidelines provided on page 1-2.



3-2

Advanced Touch Screen Functions The following is an overview of the touch screen functions for standard machine operation. For details on other touch screen functions:

• Troubleshooting screens (see page 6-2) • Status screens (see page 6-9)

Main Menu

See description on page 3-3






Chapter 3: Advanced Operation


3-3

Run Screen


FEED (group) Use these buttons to select the Feed Mode (see page 2-16 for details): • Feed Off: Select Manual Feed Mode, where you manually feed in and clamp

the door (see Manual Run screen on page 3-4). Note: This is the power-up default (other selections are not retained after cycling power.)

• Auto Feed: The door is automatically fed in, clamped in the appropriate location, cut per the information from the downloaded door file, and fed out to the next machine or assembly table when it is ready.

• Feed Thru: Doors are not processed by the DL-NCB. Rather, they are fed from the in-feed end of the machine to the out-feed end, without clamping and cutting.

• Rev Feed: Like Auto Feed, but doors are fed in from the out-feed end of the machine.

SELECT TOOL (group)

These two buttons select which tool is used for cutting steel or fiberglass doors. For example, if the buttons read Steel #1 and Fiberglass #4, tool #1 will be used for cutting a steel door and tool #4 will be used for cutting a fiberglass door.

Disable Tools Opens a pop-up, where you can turn off any of the four tools. If a tool is disabled (OFF), the changer will not attempt to use it, and it’s icon will show as red. Refer also the Disabling Tool Holder Locations procedure on page 3-17.


Eject 1 Manually turns on/off the Eject function. When the Eject function is on, the cutout slug is physically knocked out with a air cylinder after the cut is complete.

Oscillate Manually turns on/off bit oscillation. When on, the cutting tool reciprocates, increasing bit life. NOTE: As shipped from the factory, the DL-NCB allows oscillation on all 4 tools. However, this touchscreen setting will have no effect if you set the tool’s Oscillate value to zero in Calibration Page 2 of the KVAL 2006 interface. (See page 3-34 for instructions to access calibration pages.)

Security Lock Manually turn on/off Security Lock Mode. When on, the tool does not plunge all the way through the door.

Download Received

Indicates if the DL-NCB has a door file downloaded to it and is available to be run.



Manual Run Go to Manual Run menu (see page 3-4)

Pop-up



3-4

Manual Run Screen


Auto Adjust Enable or disable auto-adjust feature. If enabled, the fence width adjusts to the size of the incoming door. If disabled, no door width adjustment is made. It retains its state after power is turned off.

Auto Feed Enable or disable auto-feed feature. If enabled, the auto-feed system operates normally (see page 2-17 for details). If disabled, the feed system must be operated manually.

Setup Turn on/off setup mode. While in setup mode, the machine goes through all operations as it would normally, but the cutter does not plunge into cut the door. It is used to test new templates before actually cutting a door.

Feed (speed) Manually puts the feed speed into slow. While depressed, manual feed forward (FWD) and manual feed reverse (REV) runs at a much slower speed. This is used for manually positioning the door in locations other then one of the two stops.

Open, Close Use these buttons to manually open or close the adjustable fence to accommodate doors of different sizes.

FWD, REV Use these buttons to manually position the door. FWD jogs the door forward, REV jogs the door in reverse. The feed moves as long as the button is being pressed.

Clamp Use this button to manually clamp and unclamp the door.

Stop Use this button to manually raise and lower the door stop. The left-hand stop (Primary Stop) will be used when a left-hand (LH) door is downloaded. The right-hand stop (Secondary Stop) will be used when a right-hand (RH) door is downloaded.

Download Received Indicates if the DL-NCB has a door file downloaded to it and is available to be run.


DLNCB I/O Status Go to DL-NCB I/O Status screens (see page 6-9)





3-5

Tool Changer Screen

Button or Display Description

Status Displays:

Motor Enabled = Cutter motor is not running. = Cutter motor is running.

Speed 1 = Steel cutter speed off. = Running at steel cutting speed.

Speed 2 = Fiberglass cutter speed off. = Running at fiberglass cutting speed.

Motor Warm-up = Cutter not in warm-up mode. = Cutter in warm-up mode.

Motor Stopped = Cutter motor is moving. = Cutter motor is stopped.

Changer Extended

= Tool changer clamping cone is retracted and clamped. = Tool changer clamping cone is extended.

Tool In = No Tool found in cutter motor = Tool detected in cutter motor

Tool Locked = Cutter motor clamping cone not locked. = Cutter motor clamping cone locked.

Move Cutter to Access Location

Moves the cutter gantry to a location close to the Tool Changer access gate, so the operator can manually change tools. The STOP button on the Operator’s Station must be pressed for the manual tool changer air valve to be activated.

Start Tool Calibration

Enters the Tool Changer calibration menu. For details on calibrating the Tool Changer, see page 3-21.

Tools Found In Holder

Identifies if tools were detected in the tool holders at the time of the last scan (which takes place during the homing operation). The example shown above shows that tools were detected in tool holder positions 2-4, but there was no tool in position 1.

Current Tool In Use

Identifies which tool is presently in the Cutter Head. The example shown above shows that the tool from position 1 is in the Cutter Head.



Back Return to previous screen.



3-6

Machine Data Screen

Button or Display Item Description

Total Doors Identifies the total number of door cycles run during the life of the machine.

Daily Totals Identifies the total number of door cycles run since the last Reset Change Count. This is often used to get daily production counts.

Reset Daily Total Sets the value in “Daily Totals” to zero

Reset Change Count Sets the value in “Tool Change Total Count” to zero




Creating and Saving New Templates The DL-NCB uses three types of templates to create specific cuts. The templates can then be selected from the Template Item List to be used in a Door Item List. Thus, a door can consist of one or more templates.

The three types of templates and their uses are:

• Rectangle – for cutting out rectangular holes. In the Template List, rectangles are denoted with “(CUT)”.

• Hole – for cutting out circular holes. In the Template List, holes are denoted with “(HOLE)”. • Special – for cutting out holes that that are other than circles or rectangles (e.g., oval,

diamond, etc.). In the Template List, specials are denoted with “(DLSP)”.



3-7

Creating and Saving a New Rectangle Template Use procedure below to create a new template for a rectangular cut. To later modify the template, see the instructions on page 3-9. If you wish to make a temporary modification to a template (not save it, but make a cut with the temporary changes), see page 2-20 for temporary door files, or page 2-21 for saved door files. To create a new template based on an existing template, see page 3-10.

To Create a New Rectangle Template

1. Click the List Title until it reads Template List.

2. Click on the Template Type button until it says Type Rectangle.

3. Click the Edit Off button until the button name changes to Edit On and flashes.

4. In the Template List field, type the name of the new cutout you want to create, and then press the Enter key. For example, to name the new template “1099” it would look like:

5. In the Template List, find the

template that you just created, and double click on it. This allows you to edit the following cut parameters, as necessary:

• X Location: Distance from the top of the door to the top of the cut. • Y Location: Distance from the lock side of the door to the edge of the cut.

NOTE: For the auto-centering feature to work, the Y Location must be set so the cut is centered on a 36-inch wide door. For example, to center a 20” wide cut, the Y Location would be set to 8”. Use the formula

Y Location = (36 – Cut Width) / 2

• Length: The length of the cut along the X axis, starting from the X Location. • Width: The length of the cut along the Y axis, starting from the Y Location. • The corner radiuses:

o UL Radius (upper left) o LR Radius (lower right) o UR Radius (upper right) o LL Radius (lower left)

6. When finished, click the Edit On button until the button name changes to Edit Off. 7. Save the template. Click Save and then click OK to Change Lock Template?.

NOTE: To create a round-top, set the UL and UR radiuses equal to ½ the Width.



3-8

Creating and Saving a New Hole Template Use the following procedure to create a new template for a hole, or circular, cut.

To later modify the template, see the instructions on page 3-9. If you wish to make a temporary modification to a template (not save it, but make a cut with the temporary changes), see page 2-20 for temporary door files, or page 2-21 for saved door files. To create a new template based on an existing template, following the process on page 3-10.

To Create a New Hole Template


2. Click on the Template Type button until it says Type Hole.


4. In the Template List field, type the name of the new cutout you want to create, and then press the Enter key. For example, to name the new template “PEEP-1” it would look like:


template that you just created, and double click on it. This allows you to edit the following cut parameters, as necessary:

• X Location: Distance from the top of the door to the center of the hole. • Y Location: Distance from the lock side of the door to the center of the hole. • Hole Diameter: The diameter of the hole. The hole cut is started from the X and Y coordinates,

moves out by the radius of the hole, and then cuts clockwise to complete the hole.

• Opcode: By adding a value to the Opcode field, special functions can be invoked.

6. When finished, click the Edit On button until the button name changes to Edit Off.

7. Save the template. Click the Save button and then click the OK to Change Lock Template? button.

Opcode Function 20 Shallow Plunge – Do not go all the

way through door 30 Slow Plunge – Slow down plunge

operation. Also does not do spiral as it plunges.

40 Does both code 20 and 30. 1000 Lock Y Location – Force Y location

to remain constant.



3-9

Creating and Saving a New Special Template A special is anything that is not a rectangle or hole. For example, a special could be an oval or diamond shape. Specials are developed by Kval and associated with a “Special Sub #”. When you create the template, you provide the X and Y coordinates for a specific Special Sub #.

To later modify the template, see the instructions on page 3-9. If you wish to make a temporary modification to a template (not save it, but make a cut with the temporary changes), see page 2-20 for temporary door files, or page 2-21 for saved door files. To create a new template based on an existing template, following the process on page 3-10.

To Create a New Special Template


2. Click on the Template Type button until it says Type Special.


4. In the Template List field, type the name of the new cutout you want to create, and then press the Enter key. For example, to name the new template “D16” it would look like:


template that you just created, and double click on it. This allows you to edit the cut parameters (typical parameter modifications are listed below – contact Kval for guidance): • X Location & Y Location to set

the start cut location • Special ID to enter a short

description (can be left blank) • Special Sub # to select the

desired template


7. Save the template. Click the Save button and then click the OK to Change Lock Template? button.



3-10

Creating a New Template from an Existing Template This section describes how to make a new template based on an existing template. For instructions on creating new templates from scratch, refer to page 3-6.

To Create New Template Bases on Existing Template

1. Click the Door or Lock button until you see the “Template List.” 2. Locate the targeted template in the List and double-click on it.

This displays the specifications (edit fields) for that template.

Tip: If the list is long, instead of scrolling to search for the template, you can start typing the name of the template in the Template List field above. The list automatically scrolls to the closest matching text string.

↓


4. Click on the Lock Name parameter, type the new name you want to assign to the new template, and press the Enter key. For example, if you are using a template called “011SL” to create a new template called “999” it would look like:

5. You can now edit the fields you want to change. For details about the fields to edit for each

template type, see the pages describing how to create new templates: • For rectangular cuts, see page 3-7. • For hole cuts, see page 3-8. • For special cuts, see page 3-8.


7. To save the changes to the template, click the Save button and then click the OK to Change Lock Template? button. A new template should now be added to the Template List.



3-11

Modifying (Permanently) an Existing Template This section describes how to permanently modify an existing rectangle, hole, or special template. For instructions on creating new templates, refer to page 3-6.

NOTE: If you change a template, it will affect all door files that incorporate that particular template. The only exception is that it will not affect door files that have an asterisk at the end of the door file name (e.g., EZDOOR*) – see page 3-13 for details.

To Modify an Existing Template

1. Click the Door or Lock button until you see the “Template List.” 2. Locate the targeted template in the List and double-click on it.

This displays the specifications (edit fields) for that template.

Tip: If the list is long, instead of scrolling to search for the template, you can start typing the name of the template in the Template List field above. The list automatically scrolls to the closest matching text string.

↓

3. Click the Edit Off button until the button name changes to Edit On and flashes. 4. You can now edit the fields you want to change. For details about the fields to edit for each

template type, see the pages describing how to create new templates: • For rectangular cuts, see page 3-7. • For hole cuts, see page 3-8. • For special cuts, see page 3-8.


6. To save the changes to the template, click the Save button and then click the OK to Change Lock Template? button.



3-12

Deleting Templates If you no longer need a template, you can delete it permanently from your template list.

CAUTION: Once a Door File or Template is deleted, there is no way of getting it back. It is up to the user to backup machine files so the system can be restored in the event of a

computer failure or accidental deletion of critical data. Refer to page 4-1 for file back-up guidelines and procedures.

To Delete a Template

↓

1. Click the Door or Lock button until you see the “Template List.” 2. Click the Edit Off button until is reads Edit On (flashes). 3. In the list, click on the template you wish to delete. 4. Press the Delete button and then click the About to Delete OK? button

to delete the template, or click the Delete Cancel button to cancel the delete action.

5. Repeat Steps 3 & 4 for each template you wish to delete. 6. When finished, click the Edit On button until the button name changes to Edit Off.



3-13

Creating and Saving a Permanent Door File This section describes how to create a permanent door file. The door file contains the specifications for the door and the cuts to be made. Each cut (rectangle, hole, or special) is derived from a template. To streamline your operation, you should create permanent door files for standard doors.

You can create a new permanent door file from scratch, or you can derive the new door file from an existing door file. Once a permanent door file is created, you can execute the file in two different ways: • Find the door file in the Door List, double-click door file name, and click the Down Load

button to initiate the cutting process. See page 2-21 for additional details. • Use a barcode and barcode scanner to select and execute the appropriate door file for the

incoming door. Contact Kval for help with setting up the barcode operation.

To modify an existing door file, see the instructions on page 3-15. To delete a door file, see page 3-15.

TIP: If you want the door file parameters to stay the same, even if the templates are later changed, put an asterisk at the end of the door file name when you create the file (e.g., EZDOOR*).

Creating a New Permanent Door File

↓

1. Click the Door or Lock button until you see the “Door List.”

2. Click the Edit Off button until is reads Edit On (flashes). 3. Type the name of new door in Door List field. For example, to name

the new door “EZDOOR” it would look like this: 4. Press the Enter key. This creates a new door file and opens the

Door Item List. 5. Add a template to the door file:

a. Click the Add Item button to begin the process of adding a template to the door file. Notice that the list of doors is replaced by a list of all available templates.

b. In the template list, find the template you want to add and then double-click it.

In this example, we used the 011SL cut. Notice that the name of template now shows in the field at the top of the list, the name of the door appears as the first item in the door list, and the template specifications are displayed.

c. Click the Add Item button again. This assigns the template to the new door file, and places the template name and its basic specifications in the Door Item List.

6. To add more templates, click the Edit Off button until is reads Edit On (flashes), then repeat the add-template process in Step 5 above. As

more templates are added to the door file, they are displayed in the Door Item List. In this example we added the DB1[2] hole template.

7. When you are finished adding templates, click the Edit On button until is reads Edit Off.

8. To save the door file, click the Save button and then click the OK to Save Door Template? button.



3-14

Creating a Permanent Door File from an Existing Door File Use the following procedure if you intend to derive a new door file from an existing door file.

1. Click the Door or Lock button until you see the “Door List.” 2. Click the Edit Off button until is reads Edit On (flashes). 3. Find the existing door in the list and double-click on it to view its

parameters in the Door Item List. 4. Click on Door ID #, type the name of the new door file in the field

below Door ID #, and press the Enter key. For example, if the name of the existing door is “321DOOR” and you wish to call the new door file “DOORY” it would look like:

5. Click the Save button, and then click the OK to Save Door Template? button. This creates a

new door file (a copy of an existing file, but with a new name). 6. Click the Door or Lock button until you see the “Door List.” 7. Locate the new door in the list and double-click it to view its parameters in the Door Item List. 8. Add templates to the door file, as needed. If you do not need to add templates, skip to Step 9.

a. Click the Add Item button to begin the process of adding a template to the door file. Notice that the list of doors is replaced by a list of all available templates.

b. In the template list, find the template you want to add and then double-click it. Notice that the name of template now shows in the field at the top of the list, the name of the door appears as the first item in the door list, and the template specifications are displayed.


d. To add more templates, click the Edit Off button until is reads Edit On (flashes), then repeat the add-template process in Steps 8.a. through 8.c. above. As more templates are added to the door file, they are displayed in the Door Item List.

↓

9. Remove templates from the door file, as needed. If you do not need to remove templates, skip to Step 10.

a. Click the Edit Off button until is reads Edit On (flashes). b. In the Door Item List, select the template you wish to delete. c. Press the Delete button and then click the About to Delete OK? to delete the

template, or click the Delete Cancel button to cancel the delete action. d. To remove more templates, repeat Steps 9.b. and 9.c. for each template.

10. When you are finished adding and removing templates to the door file, click the Edit On button until is reads Edit Off.

↓

11. To save the new door file, click the Save button and then click the OK to Change Door Template? button.



3-15

Modifying (Permanently) an Existing Door File Use the following procedure to permanently modify an existing door file.

To Make a Permanent Modification to an Existing Door File

1. Click the Door or Lock button until you see the “Door List.” 2. Locate the targeted door file in the List and double-click on it.

This displays the specifications for that door file.

Tip: If the list is long, instead of scrolling to search for the door file, you can start typing the name of the door file in the Door List field above. The list automatically scrolls to the closest matching text string.

3. Click the Edit Off button until is reads Edit On (flashes).

4. Add templates to the door file, as needed. If you do not need to add templates, skip to Step 5. a. Click the Add Item button to begin the process of adding a template to the door file.

Notice that the list of doors is replaced by a list of all available templates. b. In the template list, find the template you want to add and then double-click it.

Notice that the name of template now shows in the field at the top of the list, the name of the door appears as the first item in the door list, and the template specifications are displayed.


d. To add more templates, click the Edit Off button until is reads Edit On (flashes), then repeat the add-template process in Steps a through c above. As more templates are added to the door file, they are displayed in the Door Item List.

↓

5. Remove templates from the door file, as needed. If you do not need to remove templates, skip to Step 6.

a. Click the Edit Off button until is reads Edit On (flashes). b. In the Door Item List, select the template you wish to delete. c. Press the Delete button and then click the About to Delete OK? to delete the

template, or click the Delete Cancel button to cancel the delete action. d. To remove more templates, repeat Steps b and c for each template.

6. (Optional) Normally, the templates you assign to a door file are global (i.e., if you edit the template – see page 3-11 – it will affect all door files that use that template). However, you can make the templates tenant to the door file (unaffected by changes outside the door file). To do this, use the following procedure:

a. Click on Door ID and type in the name of the door followed by an “*” and press the Enter key. For example: if a door was called 1234 rename it to 1234*.

b. Edit the template parameters as needed.

7. When you are finished adding and removing templates to the door file, click the Edit On button until is reads Edit Off.

8. To save the new door file, click the Save button and then click the OK to Change Door Template? button.



3-16

Deleting a Door File If you no longer need a door file, you can delete it permanently from your door file list.

CAUTION: Once a Door File or Template is deleted, there is no way of getting it back. It is up to the user to backup machine files so the system can be restored in the event of a

computer failure or accidental deletion of critical data. Refer to page 4-1 for file back guidelines and procedures.

To Delete a Door File

↓

or

1. Click the Door or Lock button until you see the “Door List.” 2. Click the Edit Off button until is reads Edit On (flashes). 3. In the list, click on the door file you wish to delete.

To select multiple doors, use the shift-click method or the Ctrl-click method.

4. Press the Delete button and then click the About to Delete OK? to delete the template, or click the Delete Cancel button to cancel the delete action.

5. Repeat Steps 3 & 4 for each door file you wish to delete. 6. When finished, click the Edit On button until the button name changes to Edit Off.



3-17

Automatic Tool Changer The DL-NCB is equipped with an automatic tool changer. When a door file is downloaded, the DL-NCB determines if a tool change is needed, based on door material defined in the door file. If a tool change is needed, the DL-NCB follows this process to change the tool: 1. Moves to the Tool Changer. 2. If required, the machine scans the tool holders and records which tool holder positions are

empty. This is only done if a scan has not been done since the access gate was last opened. 3. The machine moves first to the empty location where the current tool is to be returned to, and

returns the tool. After the current tool is returned, the machine moves to the location of the next tool to be used and picks it up.

4. When the tool change is complete, the DL-NCB moves to the cut start location and continues with normal operation.

If the tool changer does not detect a tool or if it encounters any other problem, then the KVAL 2006 software will display an error message on the Operator’s Station monitor, indicating the problem and how to remedy the problem. If recalibration is needed, refer to the Tool Changer calibration procedures found on page 3-21.

Note: The DL-NCB retains, in memory, the tool it had at the time it was shut down. If you change the tool while the machine is off, make sure that the only empty tool slot that is not disabled is for the tool currently in the Cutter Head on the machine. For details on how to disable tool holder locations via the Touchscreen interface, refer to the Disabling Tool Holder Locations section below.

Disabling Tool Holder Locations If a tool is missing from one of the tool holder forks or if a fork is damaged, that location should be disabled via the Run Touchscreen using the Disable Tools pop-up screen. The tool changer functionality can be completely disabled if all the individual tools are disabled. This is useful in the case where there is a mechanical failure with some part of the tool changer.

To access the Run screen, press the Run or Run Menu button from any of the following screens:

Main Menu screen Manual Run screen Machine Data screen

Press these buttons to enable or disable tool locations.

ON = enabled OFF = disabled

Pop-up



3-18

Changing a Tool Manually For normal operations, the tool is changed automatically, where the DL-NCB is programmed in the Door File to select the tool appropriate to the door material. However, you can manually change the tool if you wish (for example, to change a dull bit, if there is a mechanical problem with the tool changer, or if you want to replace the tool when the machine is off).

To Change a Tool Manually

NOTE: After you manually change the tool, you will also have to home the machine – see Homing the DL-NCB on page 2-14 for instructions.

1. With one hand, hold the tool firmly (grasp by the collet).

Be sure to hold it firmly, as it would otherwise fall when it is released from the motor.

2. Using your other hand, pull out the black Tool Release button on the top left side of the motor to release the tool from the motor spindle.

NOTE: Make sure to pull the button out until it clicks in the ON position (motor spindle stays in the unclamped position). Leave the button in this position until instructed to push it in later in this procedure.

3. Once the tool is released from the motor, slide it down and away from the motor. Set the old tool aside.

4. Using one hand, insert the new tool into the spindle. Be sure to push the tool all the way up until the collet can go no farther into the spindle

5. While holding the tool firmly in place, use your other hand to push in the Tool Release button.

Do not let go of the tool until the spindle clamping assembly pulls the collet up into place.

Grasp tool firmly by the collet.

While holding the tool with the other hand, pull this button to release the tool from the motor.



3-19

Changing a Tool Bit Use the procedure below to change the bit in a tool (involves removing the old bit from the collet and installing a new bit).

Tool (assembled) Tool (fully disassembled)

To Change a Tool Bit

1. Retrieve the open-end wrench and the collet wrench from the toolbox that ships with the machine.

2. Set the tool on a flat, stable surface. 3. As shown in the illustration below, slide the open-end wrench on the collet housing and insert

the collet wrench on the collet nut. Loosen the collet nut until the bit becomes loose.

Bit

Collet Assembly

Collet Housing

Collet

Collet Nut



3-20

4. As shown in the illustration below, remove the old bit and insert the new bit.

5. Before clamping the bit in place, make sure the distance between the top edge of the bit’s

cutting surface and the bottom of the collet is 1-1/16 inches.

6. As shown in the illustration below, use the open-end wrench to hold the collet in place and

use the collet wrench to tighten the bit firmly in the collet.

1-1/16"



3-21

Calibrating the DL-NCB This section provides detailed procedures for calibrating the Tool Changer (see below) and for calibrating the cut accuracy (see page 3-33).

Note: If, after making the initial calibrations, you discover cut inaccuracy, refer to the streamlined remedy procedures in the Troubleshooting chapter (see Correcting Cut Accuracy Problems on page 6-12).

Calibrating the Tool Changer The tool changer must be calibrated to make sure the DL-NCB can find and select the appropriate tool when the program calls for it.

There are three potential stages you can use for calibrating the Tool Changer:

• Tool Calibration, Stage 1: Calibration Bolt • Tool Calibration, Stage 2: Tool Offset • Tool Calibration, Stage 3: Tool Holders

Determining Which Calibration Stage to Use Use the following as a guide to find out which Tool Calibration stage is required:

• If the error message “Tool Change Error. Calibration Bolt Not Aligned” is displayed, Tool Calibration Stage 1 is required.

• If there is difficulty retrieving the tool in position #1, Tool Calibration Stage 2 is required. • If a new tool holder has been installed or if the tool in position #1 can be retrieved correctly

but there is difficulty retrieving the tools in the other positions, Tool Calibration Stage 3 is required.

NOTE: Before calibrating the Tool Changer, you must first complete the Preparing to Calibrate

the Tool Changer procedure (see below).

Preparing to Calibrate the Tool Changer 1. If the machine is presently processing doors, do one of the following:

a. If you need to cancel a cut in progress, in the KVAL 2006 interface, press the ABORT button (or press the F1 key) and then the Restart button (or press the F2 key).

b. If you wish to finish the present door, but prevent any subsequent doors from being processed, in the KVAL 2006 interface, press the Override Count button.



3-22

2. Access the Tool Changer screen on the Touchscreen interface. The Tool Changer screen can be accessed by pressing the Tool Changer button from any of the following three touch screens:

Main Menu screen

Run screen

Manual Run screen

3. In the Tool Changer screen, click the Start Tool Calibration button to access the main Tool Calibration screen.

Tool Changer screen Tool Calibration main screen

4. After you access the Tool Calibration screen, proceed to the calibration procedure prescribed by the Determining Which Calibration Stage to Use guidelines on page 3-21. Stage 1: go to page 3-23. Stage 2: go to page 3-27. Stage 3: go to page 3-31.



3-23

Tool Calibration, Stage 1: Calibration Bolt Use Stage 1 to center the Calibration Eye to the Calibration Bolt.

1. Clear the “Tool Change Error. Calibration Bolt Not Aligned” alert. You will correct the calibration in the remaining steps of this procedure.

2. Make sure all tool positions are disabled.

a. On the Main Menu of the Touchscreen, press the Run Screen button to view the Run Screen. Then click the Disable Tools button to view the Disable Tools pop-up screen.

Main Menu

b. Make sure all Tool positions are disabled (OFF). If any Tool buttons are set to ON, press them so they display OFF. It should look like the screen shown above.

3. Home the machine. For instructions, refer to Homing the DL-NCB on page 2-14.

4. Navigate to the main Tool Calibration screen (for navigation help, see page 3-22) and press the Stage 1 button to access the Stage 1 screen.

Tool Calibration screen Tool Calibration – Stage 1 screen

5. Press the Toggle Head Position button one time and verify that the machine moves cutter head to a position approximately five inches away from the Calibration Bolt..

6. Press the Toggle Head Position button one more time. This will move the carriage so the Calibration Eye should be over the Calibration Bolt. If the eye is not centered over the Calibration Bolt, follow the steps listed below.

Run Screen

Pop-up



3-24

↓

7. In the KVAL 2006 interface, click once on the Maint button. 8. Click the Cal button.

You will see a message pop up in front of the graphic display area. This is a warning message, informing you that if you proceed, it will abort any cutout program that is running.

Click on the pop-up message to proceed. 9. Click the Cal OK? button. The Calibration Menu page appears:

10. Click the Calibration button. This takes you to the calibration pages where the calibration

takes place. The first page displayed is Calibration Page 1:



3-25

11. Click the Page up button twice to access Calibration Page 3 (Tool Changer Calibration):

12. Look at the placement of the Calibration Eye relative to the Calibration Bolt. Measure and record any misalignment along the X axis (length of the machine) and along the Y axis (across the width of the machine). Any misalignments will be entered as offsets in the Calibration Page as noted below.

13. If the Calibration Eye is out of alignment along the X axis (length of DL-NCB), adjust the Tool Alignment according to the following sub-procedure. If there is no misalignment along the X axis, skip to Step 14.

a. Locate the Tool Alignment Bolt X(1) area on the Calibration Page. b. Integrate the Modifier (if needed):

If the right-hand field has a value other than zero, click the left-most field to integrate the value. The result should update the left-most field. Before proceeding to the next step, verify that the right-hand field is empty or shows zero.

Example:

(Modifier field has a non-zero value)

↓

(Click on the left-most field) ↓

(Offset is updated, Modifier field is empty)

c. Type the offset in the right-hand field, press the Enter key, and then click the left-most field to register the new offset. If the Calibration Eye needs to move toward the out-feed end of the machine, enter a negative value. If the Calibration Eye needs to move toward the in-feed end of the machine, enter a positive value.



3-26

Example:

If the Calibration Eye needs to move ¼ inch toward the out-feed end of the machine, type “-1/4” or “-0.250” in the field and press the Enter key. Then click the left-most field to record the offset value. This process is illustrated below:

↓ Press Enter key. ↓

↓ Click the left-hand field (updates with final offset value). ↓

14. If the Calibration Eye is out of alignment along the Y axis (across the width of the DL-NCB

machine), adjust the Tool Alignment according to the following sub-procedure. If there is no misalignment along the Y axis, skip to Step 15.

a. Locate the Tool Alignment Bolt Y(1) area on the Calibration Page.

b. If the right-hand field has a non-zero value, click the left-most field to update the

offset before proceeding (see the Integrate the Modifier example on page 3-25). c. Type the offset in the right-hand field, press the Enter key, and then click the left-

most field to register the new offset. If the Calibration Eye needs to move toward the fixed fence side of the machine, enter a negative value. If the Calibration Eye needs to move toward the adjustable fence side of the machine, enter a positive value. (see example in Step 13.c. above)

15. When you are finished making the calibration adjustments, click the Exit button. This exits the Calibration page and the KVAL 2006 program.

16. Re-launch the KVAL 2006 program. 17. Home the machine. 18. Verify the Calibration during the homing operation:

As part of the homing operation, after the cutter head reaches the Home position, it will travel to the Tool Changer location and check to make sure the Calibration Eye is aligned with the Calibration Bolt. If the DL-NCB detects misalignment between the Eye and the Bolt, the KVAL 2006 Interface will display the following alert:

If you see the alert, clear the alert and repeat the Stage 1 procedure. If you do not see an alert, Stage 1 calibration is complete.



3-27

Tool Calibration, Stage 2: Tool Offset Use Stage 2 to calibrate the distance between the Calibration Eye and the center of the cutter motor at Tool Holder position # 1. If the cutter head has problems picking up or returning the tool to Tool Holder position #1, this is the stage that allows you to correctly calibrate the offset between the Calibration Eye and the center of the cutter motor.

1. Move the cutter head down to the in-feed end of the machine, where the tool can be removed: a. In the Touchscreen panel, from the Main Menu, press the Tool Changer button. In

the Tool Changer screen, press the Move Cutter To Access Location button to move the cutter gantry to the in-feed end of the machine.

2. If there is a tool in the cutting head remove the tool manually. IMPORTANT: Leave the tool in Tool Holder position #1 for this procedure.

a. Press the STOP button on the Operator’s Station control panel. This leaves the control circuits on and turns off all machine drives.

b. Open the Safety Gate and proceed to the Tool Changer area. c. Remove the tool from the Cutter Head:

i) With one hand, hold the tool firmly (grasp it by the collet).


ii) Using your other hand, pull out the black Tool Release button on the top left side of the motor. This releases the tool from the motor spindle.

iii) Once the tool is released from the motor, slide it down and away from the motor.

iv) Push in the black Tool Release button. v) Insert tool into the proper tool holder.

d. Make sure to leave a tool in Tool Holder position #1. e. Close the Safety Gate. f. Turn the machine back on by pressing the START button on the Operator’s Station

control panel.

Pressing this button moves the Cutter Gantry to the in-feed end of machine, for easy access.

Grasp tool firmly by the collet.

While holding the tool with the other hand, pull this button to release the tool from the motor.



3-28

3. Home the machine. For instructions, refer to Homing the DL-NCB on page 2-14.

NOTE: The homing procedure will produce the following error:

This is a normal condition for Stage 2 calibration. Click the alert pop-up to clear it and move to the next step.

4. Navigate to the main Tool Calibration screen (for navigation help, see page 3-22) and press the Stage 2 button to access the Stage 2 screen.


5. Press the Toggle Head Position button one time and verify that the machine responds as follows: • Moves the cutter head to the in-feed end of the machine. The Calibration Eye should be

over the Calibration Bolt. • Moves the Tool Changer arm in toward the center of the machine, as it does during a tool

change.

6. Press the Toggle Head Position button again and verify that the machine responds by moving the cutter head so that the center of the cutter motor is centered over Tool Holder #1.

Motor is positioned over the center of Tool #1



3-29

7. Look at the cutter motor clamping cone in relationship to the center of the collet on tool #1. If the center of the cutter motor is not centered over the tool, write down the amount it is off, both along the X axis (length of DL-NCB) and the Y axis (width of DL-NCB). Then proceed to the next step.

↓

8. In the KVAL 2006 interface, click once on the Maint button. 9. Click the Cal button.


Click on the pop-up message to proceed. 10. Click the Cal OK? button. The Calibration Menu page appears:

11. Click the Calibration button. This takes you to the calibration pages where the calibration

takes place. The first page displayed is Calibration Page 1:



3-30

12. Click the Page up button twice to access Calibration Page 3 (Tool Changer Calibration):

13. Regarding the cutter motor clamping cone in relationship to the center of the collet on tool #1, if the cutter motor is out of alignment along the X axis (along the length of DL-NCB), adjust the Tool Location Offset according to the following sub-procedure. If there is no misalignment along the X axis, skip to Step 14.

a. Locate the Tool Location Offset X(1) area on the Calibration Page. b. If the right-hand field has a non-zero value, click the left-most field to update the

offset before proceeding (see the Integrate the Modifier example on page 3-25). c. Type the offset in the right-hand field, press the Enter key, and then click the left-

most field to register the new offset. If the cutter motor needs to move toward the out-feed end of the machine, enter a negative value. If the cutter motor needs to move toward the in-feed end of the machine, enter a positive value. Example:

If the cutter motor needs to move ¼ inch toward the in-feed end of the machine, type 1/4” or “0.250” in the field and press the Enter key. Then click the left-most field to record the offset value. This process is illustrated below:

↓ Press Enter key. ↓

↓ Click the left-hand field (updates with final offset value). ↓

14. If the cutter motor is out of alignment along the Y axis (across the width of the DL-NCB

machine), adjust the Tool Location Offset according to the following sub-procedure. If there is no misalignment along the Y axis, skip to Step 15.

a. Locate the Tool Location Offset Y(1) area on the Calibration Page.

b. If the right-hand field has a non-zero value, click the left-most field to update the

offset before proceeding (see the Integrate the Modifier example on page 3-25).



3-31

c. Type the offset in the right-hand field, press the Enter key, and then click the left-most field to register the new offset. If the cutter motor needs to move toward the fixed fence side of the machine, enter a negative value. If the cutter motor needs to move toward the adjustable fence side of the machine, enter a positive value. (see example in Step 13.c. above)

15. When you are finished making the calibration adjustments, click the Exit button. This exits the Calibration page and the KVAL 2006 program.

16. Re-launch the KVAL 2006 program. 17. Click on the Abort button, then the Load Programs button at the bottom right corner of the

KVAL 2006 interface screen. 18. Stage 2 calibration is complete.

Tool Calibration, Stage 3: Tool Holders Use Stage 3 to fine-tune the alignment of the cutter motor with one or more tool holders. In this process, you loosen the tool holders where the tool is not being retrieved correctly, then move the cutter motor (with a tool inserted) from one tool holder to the next, tightening each tool holder as you go.

This alignment is usually required only when the machine is being set up for the first time or if the tool holder has just been replaced.

1. Turn off the machine by pressing the STOP button on the Operator’s Station control panel. This leaves the control circuits on and turns off all machine drives.

2. Open the gate near the tool changer. 3. Remove the tools from all tool holders where the tool is not being retrieved correctly. Refer to

the photos below for proper tool removal technique.

Push the tool out, using both hands. Tool is released from Tool Holder

NOTE: If there is an empty tool position that does not need calibration, disable the tool position. Refer to the instructions on page 3-17.



3-32

4. If a tool is not already inserted in the Cutter Head, manually insert a tool into the cutter head:

a. Locate the black Tool Release button on the top left side of the motor.

b. Using one hand, pull out the Tool Release button. The clamping cone on the cutter head will come down. Leave the Release button in the ON (pulled out) position.

c. Using your other hand, insert the tool into the motor spindle. Be sure to push the tool all the way up until the tool can go no farther into the spindle.

d. While holding the tool firmly in place, push in the Tool Release button.

Do not let go of the tool until the tool is pulled up into place.

5. Using a ½-inch hex wrench, loosen the empty tool holders just enough so they will move a little bit.

6. Close the safety gate. 7. Turn the machine back on by pressing the START button on the Operator’s Station control

panel. 8. Home the machine. For instructions, refer to Homing the DL-NCB on page 2-14. 9. Navigate to the main Tool Calibration screen (for navigation help, see page 3-22) and press

the Stage 3 button to access the Stage 3 screen.


10. Press the Next Step button one time and verify that the machine responds as follows:

• The cutter head moves down to the Tool Changer and scans the Calibration Bolt. • It will then scan all the tool holders to see which ones are empty (it will only move the tool

with the collet into the tool holders that do not already have a tool in them.). • The cutter head will move the tool into the first available empty tool holder.



3-33

11. Repeat the following sub-procedure to fine-tune the position of each empty tool holder:

a. Open the gate. b. Tighten the tool holder bolts securely. c. Close the gate and return to the Operator’s Station.

d. In the KVAL 2006 interface, press , then . e. If there is another tool holder that remains to be tightened, press the Next Step

button. The head will move the tool into the empty tool holder.

12. After all the tool holders are bolted securely in place, Stage three is complete.

NOTE: Be sure to close the Safety Gate.

13. Press the BACK button as needed to exit to the desired screen on the Touchscreen panel. 14. Replace all tools to their respective Tool Holder positions. 15. Stage 3 calibration is complete.

Calibrating Cut Accuracy The DL-NCB needs to be calibrated so that the cuts and holes are started at the correct X and Y coordinates.

To Calibrate the Cut Accuracy

1. Create a baseline cut on a LH (left-hand) door. LH doors use the Primary Stop (located at the out-feed end of the machine):

a. Create and download a LH door file to make a rectangular cut with these specifications: 10 inches from the top (X) and 10 inches from the side (Y), 5 inches long and 5 inches wide.

b. Measure the cut accuracy. Measure the distance from the top of the door to the top of the cut (X axis), and measure the distance from the side of the door to the nearest side of the cut (Y). Write down these measurements and note any inaccuracies from the expected values.

2. Create the same baseline cut, from Step 1, on a RH (right-hand) door. RH doors use the Secondary Stop (located at the in-feed end of the machine).

Feed Direction

Primary Stop X = 10"

Y = 10" 5x5 cut

Top of Door

Lock Side Hinge Side

Feed Direction

Secondary Stop

X = 10"

Y = 10" 5x5 cut

Top of Door

Lock Side Hinge Size



3-34

3. If there are inaccuracies in the cuts, adjust the calibration settings:

↓

a. In the KVAL 2006 user interface, click once on the Maint button. b. Click the Cal button.


Click on the pop-up message to proceed. c. Click the Cal OK? button. The Calibration Menu page appears:

d. Click the Calibration button. This takes you to the calibration pages where the

calibration takes place. The first page displayed is Calibration Page 1:

Note: Z Calibration is not used.



3-35

e. If there is inaccuracy in the X coordinate for cuts on an LH door, adjust the Primary Stop setting. Otherwise, skip to Step f.

i) Locate the Primary Stop-Outfeed(1) area on the Calibration Page. ii) If the right-hand field has a non-zero value, click the left-most field to update the

offset before proceeding (see the Integrate the Modifier example, page 3-25). iii) Type the offset in the right-hand field, press the Enter key, and then click

the left-most field to register the new offset. If the cut needs to move toward the top of the door, enter a negative value. If the cut needs to move away from the top of the door, enter a positive value. For example, if the cut needs to move ¼ inch toward the top of the door, type “-1/4” or “-0.250” in the field and press the Enter key. Then click the left-most field to record the offset value. This process is illustrated below:

↓ Press Enter key. ↓ Click the left-hand field (updates with final offset value). ↓

f. If there is inaccuracy in the X coordinate for cuts on an RH door, adjust the

Secondary Stop setting. Otherwise, skip to Step g. i) Locate the Secondary Stop-Outfeed(1) area on the Calibration Page.

ii) If the right-hand field has a non-zero value, click the left-most field to update

the offset before proceeding. iii) Type the offset in the right-hand field, press the Enter key, and then click the

left-most field to register the new offset. If the cut needs to move toward the bottom of the door, enter a negative value. If the cut needs to move away from the bottom of the door, enter a positive value. (see example in Step e.iii. above)

g. If there is inaccuracy in the Y coordinate for the cut, adjust the Y Calibration setting. Otherwise, skip to Step h.

i) Locate the Y Calibration(1) area on the Calibration Page.

ii) If the right-hand field has a non-zero value, click the left-most field to update

the offset before proceeding. iii) Type the offset in the right-hand field, press the Enter key, and then click

the left-most field to register the new offset. If the cut needs to move toward the fixed fence of the DL-NCB, enter a negative value. If the cut needs to move away from the fixed fence of the DL-NCB, enter a positive value. (see example in Step e.iii. above)

h. When you are finished making the calibration adjustments, click the Exit button.

This exits the Calibration page and the KVAL 2006 program.

4. Re-launch the KVAL 2006 program. 5. Click on the Abort button, then the Load Programs button at the bottom right corner of the

KVAL 2006 program screen.



3-36

6. VALIDATION: To verify that the calibration is correct and the cuts will be accurate, repeat Steps 1 and 2 to make new cuts and measure for any error. Repeat the same cuts on new doors, or make new cuts on the same doors but with these specifications:

o 8 inches from the top (X) and 8 inches from the side (Y) o 9 inches long and 9 inches wide

7. If there are inaccuracies in the cuts, adjust the calibration settings accordingly (refer back to Step 3 above), and then redo the validation.


Chapter 4: System IT Administration This chapter describes how to administer the IT for the DL-NCB system.

System Architecture For optimum support the DL-NCB requires internet access. The computer is equipped with two LAN connections. One is dedicated to the DL-NCB the other is available for internet connection.

The following sites are needed:

• Kval’s website: http://www.kvalinc.com/home.html

• Website for remote technical support for your machine: http://www.gotoassist.com/

Backing up System Files Back up is recommended for the following directories:

• C:\doorlite

• C:\dataline


Chapter 5: Maintenance This chapter describes how to maintain the DL-NCB system. This chapter contains the following information:

• Maintenance schedule ................................................................................................ 5-1 • Lubrication requirements ........................................................................................... 5-2 • Maintaining the cutter motor spindle ......................................................................... 5-6

Maintenance Schedule Kval recommends the following maintenance schedule to ensure proper machine operability.

Daily • Blow off dust from the entire machine. • Lubricate linear bearings and chrome shaft with silicone (see lubrication requirements on

page 5-2). • Wipe down the machine with a clean dry cloth. • Check tooling for wear. • Wipe off the photo eyes with a clean dry cloth, and check to ensure that all fastening nuts are

snug. CAUTION: Fastening nuts (as well as eyes) are plastic and threads can strip easily.

• Check the air pressure to make sure it is set at 100 psi. • Refill lubricator with an ISO 32 standard hydraulic oil (use KVAL part# SYSLUBEG).

Weekly • Check the machine for smooth motion through a complete door cycle. • Clean linear bearings and chrome shaft with a clean dry cloth, then lubricate. • Check air pressure to the machine. • Adjust and lock flow controls.

Fastening nuts

Adjustment knob

Tightening nut



5-2

• Check all air lines & electrical wiring for kinks or rubbing. • Remove and blow out air condition filters. One on the main electrical panel and one on the

operator’s station:

Lift up and pull bottom out. Remove screw and slide up.

• Visually inspect the system to check for any worn or broken parts.

May and December Checkups • Wash filter and lubricator bowls with soapy water. • Grease all bearings and tighten all bolts (see grease locations on illustrations, page 5-4).

Access to some grease fittings is difficult and will require a special needle point grease tip (supplied with your system).

• Clean and lubricate all slides and cylinder rods with dry silicone spray. • Tighten all bolts.

Lubrication Requirements This section describes the parts of the machine that require periodic lubrication, and specifies the lubricants. In addition, it explains how to maintain the lubrication systems on the machine.

Linear Bearings If the bearing is equipped with a grease fitting, it should receive 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N Lube EP-2) every 30 days. Bearings without grease fittings have been pre-lubricated at the factory and do not require further lubrication.

Flange Bearing and Pillow Blocks Use Dura-Lith grease: 1 gram every 60 days.

Approved Lubrication Products for Lubricators Chevron AW Hydraulic Oil 32 – or KVAL P/N SYSLUBG or G-C lubricants light AW R&O or Mobile DTE 24 or Shell Tellus32 or Gulf Harmony 32.

Chapter 5: Maintenance


5-3

Gear Motor Lubrication Requirements Oil change is recommended after 2000 hours or six months of operation. Use AGMA #8 gear lube or MOBILUBE HD 80 W-90 or equivalent.

Adjusting the Air Line Lubricator (not available on all machines) Using the knob on the top of the lubricator, adjust until one drop per every other cycle is used (as observed through sight glass.)

Priming the Air Line Lubricator New and used machinery run out of oil from time to time. It is a good practice to check your machine lubricator to insure that it is putting the proper dose of oil in the air lines. Usually 1 drop of oil every other cycle is a good rule of thumb.

To prime the lubricator, find an air line on the carriage section of the machine that is energized, and disconnect it, allowing the air stream to bleed air pressure away from any persons. Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose. Repeat this same procedure for the back section and other trouble areas.

Check the lines every week to two weeks.

NOTE: The Lubricator is not installed on all machines.

Main air shut-off valve

(Sight glass). Drop will form at end of cane shaped tube visible inside glass.

(Adjustment knob). When the oiler has run dry, open the knob all the way until flow begins. Once you have a steady flow, tighten knob back down until you have one drop per every other cycle.

Sight Glass. Check rate: 1 drop for every two door cycles.

Set bottom valve to 90 psi

Lubricator Regulator Filter

Set top valve to 100 psi

Adjustment Knob.



5-4

Grease Points for Carriage



5-5



5-6

Maintaining the Cutter Motor Spindle This section provides procedures related to maintaining the Cutter Motor Spindle, including:

• Checking and adjusting the spindle’s drawbar extension. This helps insure safe operation and that the Cutter Motor clamps and holds the tool securely. Kval recommends you perform this check (and adjustment if necessary) every 100 tool changes. The DL-NCB touchscreen will prompt for the adjustment.

• Cleaning and lubricating the spindle’s clamping assembly. This helps insure proper clamping and retention of the tool, as well as insure motor spindle longevity and smooth operation. Kval recommends you do this at least once a month.

WARNING: Failure to perform this maintenance at recommended intervals can result in system damage or personal injury.

Preparing the Machine for Spindle Maintenance 1. If the machine is presently processing doors, do one of the following:

a. If you need to cancel a cut in progress, in the KVAL 2006 interface, press the ABORT button (or press the F1 key) and then the Restart button (or press the F2 key).

b. If you wish to finish the present door, but prevent any subsequent doors from being processed, in the KVAL 2006 interface, press the Override Count button.

2. Move the Cutter Gantry down to the in-feed end of the machine, where the Cutter Motor can be easily accessed:

a. In the Touchscreen panel, from the Main Menu, press the Tool Changer button. In the Tool Changer screen, press the Move Cutter To Access Location button to move the cutter gantry to the in-feed end of the machine.

3. After the Cutter Gantry stops at the in-feed end of the machine, press the STOP button on the Operator’s Station control panel. This leaves the control circuits on and turns off all machine drives.

4. Shut down the computer by clicking on the “Start” button in the bottom, left corner of the computer screen and then selecting “Shutdown”. Click on “Turn Off” when prompted. When the computer screen goes blank, it is OK to proceed to the next step.

5. Push in the CONTROL TRANSFORMER switch to kill power to the machine. 6. Turn off the Disconnect Switch on the main electrical cabinet and on the smaller high-

frequency cabinet.

NOTE: Be sure to follow the lock and tag out guidelines (see page 1-5) before continuing. 7. Open the Safety Gate and walk to the Tool Changer area.

Pressing this button moves the Cutter Gantry to the in-feed end of machine, for each access.



5-7

8. Remove the tool from the Cutter Head: a. With one hand, hold the collet firmly.


b. Using your other hand pull out the black Tool Release button on the top left side of the motor to release the tool from the motor spindle.

Note: Make sure to pull the button out until it clicks in the ON position (motor spindle stays in the unclamped position). Leave the button in this position for subsequent steps in this procedure.

c. Once the tool is released from the motor, slide it down and away from the motor.

d. Set the tool aside in a safe and easily accessible location. 9. Do one of the following:

• To check the drawbar extension, proceed to Checking and Adjusting the Drawbar Extension below.

• To clean and lubricate the spindle assembly, proceed to Cleaning and Lubricating the Spindle Clamping Assembly on page 5-9.

Checking and Adjusting the Drawbar Extension Use the following procedure to check and adjust how far the spindle clamping cone extends beyond the bottom of the spindle casing. The extension is controlled by an internal drawbar. When you pull out the Tool Release button, the pneumatic activator extends the drawbar to push the clamping cone down far enough to clamp onto the collet for the tool. When you push in the Tool Release button, the pneumatic activator retracts the drawbar to draw the clamping cone up into the spindle, thereby clamping the collet securely in position.

1. Make sure you have completed the steps in Preparing the Machine for Spindle Maintenance above.

2. Retrieve the U-shaped gauge from the toolbox shipped with the machine.

3. Position the gauge over the clamping cone that extends past the bottom of the spindle casing, pressing the gauge against the bottom of the spindle casing (refer to the illustration). Check the extension with the gauge – the cone should extend 10.5mm (+/- 0.1mm) below the bottom of the spindle casing.

4. If the extension is correct, skip to Step 9. If the extension needs to be adjusted, proceed to Step 5.

Clamping Cone

Bottom of spindle casing

Gauge



5-8

5. Adjust the drawbar extension: a. With the drawbar still

extended (unclamped position, with cone extended below bottom of spindle casing), hold the cone stationery with an 18mm open-end wrench.

b. Use a 4mm Tee-Handle Allen wrench to loosen (counter-clockwise) and remove the set screw from the clamping assembly.

c. Place the set screw in a safe and easily accessible location.

d. Use the 18mm wrench to turn the cone to get the proper extension (counter-clockwise to extend or clockwise to retract), checking it with the gauge.

6. After adjusting the drawbar extension, verify that the adjustment is stable: a. Cycle the drawbar a few times (push in and pull out the black Tool Release button to

make the spindle clamp and unclamp).

Note: Stop with the drawbar extended (Tool Release button pulled out). b. Re-check the extension with the gauge. If further adjustment is necessary, repeat this

verification process. 7. Reinstall the set screw (use Blue Loctite on the threads). 8. Still holding the cone with the 18mm wrench, tighten the set screw with the 4mm Tee-Handle

Allen wrench. Torque the set screw to 14.74 ft lb (20Nm). 9. Reinsert the tool into the spindle:

a. Using one hand, make sure the Tool Release button is pulled out (released position) so the spindle can receive the tool.

b. Using your other hand, insert the tool into the spindle. Be sure to push the tool all the way up until the collet can go no farther into the spindle.

c. While holding the tool firmly in place, push in the Tool Release button.

Do not let go of the tool until the spindle clamping assembly pulls the collet up into place.

10. Close the safety gate. 11. Remove the lock out and turn the Disconnect on. 12. Turn the machine back ON. Be sure to complete the full power-up procedure (for details, see

Powering Up the DL-NCB on page 2-11). 13. Check the DL-NCB touchscreen. If there are no error messages displaying, the machine

should be ready for normal operation. However, if the “No tool in spindle” message displays, go back and reinsert the tool into the motor spindle.

Cone

18mm wrench

4mm Allen

wrench



5-9

Cleaning and Lubricating the Spindle Clamping Assembly Kval recommends you use the procedure below to remove, clean and grease the Cutter Motor’s clamping assembly at least once a month. Doing so will help ensure the cutter motor retains the cutting tool.

Clamping Assembly (shown inside spindle) Clamping Assembly (removed from spindle casing, with clamping cone and set screw unscrewed from assembly)

Set Screw

Clamping Cone

Gripper Segments

(6 total)

Brass Spacer

Drawbar

Spindle Casing



5-10

1. Make sure you have completed the steps in Preparing the Machine for Spindle Maintenance above (page 5-6).

2. With the drawbar still extended (unclamped position), hold the clamping cone stationery with an 18mm open-end wrench. And use a 4mm Tee-Handle Allen wrench to loosen (counter-clockwise) and remove the set screw from the clamping assembly.

3. Turn the cone counter-clockwise to remove it (use the open-end wrench if necessary).

Clamping Cone

Open-End Wrench

Allen Wrench

Clamping Cone



5-11

4. (1) Push one of the clamping assembly gripper segments upward (against the internal spring) and then (2) tilt it toward the center of the spindle. This will loosen the segment so you can remove it. Remove all six gripper segments in this manner.

5. Remove the brass spacer with a pair of soft jaw needle nose pliers (see illustration). USE CAUTION when working with the brass spacer as metal can damage the brass spacer.

6. With a lint-free towel:

• Clean all of the clamping assembly components with alcohol. DO NOT use any type of oil-base lube. Inspect all parts for wear and damage. Replace any or all of the warn or damaged parts (contact Kval for replacements).

• Clean the taper surface (inside surface of spindle) and ensure that the edges are rounded. If the tool is misaligned with spindle clamping assembly, the tool can damage these two areas of the spindle. The tool could hit the rim and cause a deformity or, put a gouge in the beveled surface.

Gripper Segment

(1) Push Up

(2) Tilt

Brass Spacer



5-12

7. Begin reassembling the clamping assembly by installing O-rings 1 and 2 as shown in the figure. Before inserting the O-rings, be sure to slide the protective sleeve over the threaded drawbar.

8. Lubricate the clamping cone, gripper segments, brass spacer with “Metaflux” Lube Only. Use

the brush in the can to apply a very small amount at the locations shown in figure.

O-ring 2

O-ring 1

Gripper Segment

Identifies Lube Points

Clamping Cone

Brass Spacer



5-13

9. Push the pre-assembled brass spacer up into the spindle until it rests against the spring.

10. Insert the notched end of one gripper segment, taking care that the notches on the gripper

segment slide into the notices on the brass spacer. Applying upward pressure on the spacer, (1) push the segments upward, then (2) tilt outward to lock into position. Repeat with the rest of the segments.

Gripper Segment

(1) Push Up

(2) Tilt Outward

Brass Spacer

Brass Spacer



5-14

11. Place the clamping cone upward through in the middle of gripper segments and screw the clamping cone clockwise onto the threaded drawbar using an 18mm open-end wrench.

12. Adjust the clamping cone to the proper height. The clamping cone should extend 10.5mm

(+/- 0.1mm) below the bottom of the spindle. Check it with the U shaped gauge. 13. While securing the clamping cone with the 18mm wrench, install and tighten the set screw

with the 4mm Tee-Handle Allen wrench (using blue Loctite on setscrew threads). Torque the set screw to 14.74 ft lb (20Nm).

14. Recheck the extension height with the U shaped gauge. If it is OK, the machine should be

ready for operation. 15. Close the safety gate, remove the lock out and turn the Disconnect on. 16. Turn the machine back ON. Be sure to complete the full power-up procedure (for details, see

Powering Up the DL-NCB on page 2-11).

Clamping Cone

Open-End Wrench

Gripper Segments

Drawbar

Set Screw

Open-End Wrench

Allen Wrench


Chapter 6: Troubleshooting This chapter describes how to resolve problems or error messages while operating the DL-NCB.

• Solutions to common problems ................................................................................. 6-1 • Using the touch screen’s troubleshooting utility ....................................................... 6-2 • Using the touch screen’s status displays .................................................................... 6-9 • Correcting cut accuracy problems ........................................................................... 6-12 • Troubleshooting the air cylinders ............................................................................ 6-13 • Troubleshooting electrical problems ........................................................................ 6-15 • Adjusting limit switches .......................................................................................... 6-19 • Troubleshooting photo detectors ............................................................................. 6-20 • Getting help from Kval ............................................................................................ 6-21

Solutions to Common Problems Symptom Cause Remedy Cut accuracy off. Machine calibration needs adjustment. See table on page 6-8. Not all lights on Status Light Panel are illuminated

One or more causes possible. See troubleshooting process on page 6-16.

Breaking tool holder forks on returning the tool.

1. The tool may be sticking in the motor.

2. The tool holder may be misaligned.

1. Check that the air pressure is set to 100 psi (for adjustment, see diagram on page 5-3).

2. Check alignment between Cutter Motor and Tool Holder; adjust if necessary (for adjustment, see page 3-31).

Breaking tool holder forks when getting a new tool.

The tool changer calibration may be incorrect.

See page 3-21 for Tool Changer recalibration procedures.

Main machine power will not come on

1. Disconnect switch on panel in off position

2. Transformer switch is bad 3. Fuse on transformer is blown 4. Power from shop turned off

1. Turn on switch 2. Fix switch 3. Change fuses 4. Turn on main power going to machine. Refer also to electrical troubleshooting on page 6-15.

PLC will not turn on 1. Start button is bad 2. ACR relay is bad 3. E-Stop button pushed 4. One of the gates is open

1. Change Start button 2. Replace ACR relay 3. Pull out E-Stop button 4. Close gate(s)

Machine will not home

1. PLC not turned on 2. Air not on machine

1. Press start button 2. Turn air on machine

Machine will not feed doors

1. Feed switch not turned on 2. Door on outfeed end of machine 3. Through beams are covered with

debris 4. High frequency drive for feed motor

has a fault

1. Turn feed switch to on position 2. Feed door out by pressing feed out foot

pedal 3. Blow off through beams 4. Press Reset button on high frequency

drive Machine suddenly stops in mid cycle

1. Worn or misadjusted limit switch 2. Dirty photo eye

1. Adjust limit switches (see page 6-19). 2. Clean photo eye (see page 6-20).



6-2

Using the Touch Screen’s Troubleshooting Utility Below are descriptions of the troubleshooting screens on the DL-NCB Touch Screen. A Warning pop-up screen could also be invoked by certain error conditions (see page 6-8).

Additional screens for system status are located on page 6-9.

Main Troubleshooting Menu

Go to Homing Troubleshooting Screens (see page 6-3)

Go to Plunge Troubleshooting Screen (see page 6-5)

Go to Auto-Feed Troubleshooting Screen (see page 6-6)

Go to Servos Troubleshooting Screen (see page 6-7)

Chapter 6: Troubleshooting


6-3

Homing Troubleshooting Screens

Button or Display Item Description = condition has occurred, requires attention

High Freq Drive Error One of the high frequency drives has an error. Check the drives in the high frequency electrical box (the smaller of the two electrical boxes) for errors or bad fuses.

Cutter Head Up The Cutter Head limit switch is not active, indicating that either the head is not fully retracted or the switch is bad. The most common reason for this error is that the air supply is off or low, thus the head is not fully lifted.

Eject Cylinder Retracted The eject cylinder eye is not activated, indicating that either the eject cylinder is not retracted or is not reading correctly.

Gate Open The switch on the tool access gate is open. The gate needs to be closed for the DL-NCB to home.

Galil Abort An internal signal. Kval support personal will know the meaning of this signal.

Servo Reset CR An internal signal. Kval support personal will know the meaning of this signal.

BCR An internal signal. Kval support personal will know the meaning of this signal.

Go to Homing Page 2 Go to second Troubleshoot Homing page (see description below )



6-4


Galil Inputs Off Communication problem between Galil controller and the computer.

DataLink Comm Error The I/O nodes on either the head or on the frame are not communicating correctly.

X Axis Servo Drive Fault The X axis Servo Drive has a fault on it and has stopped operation. Check fuses on drive and replace, if needed. The RESET DRIVES button on the main operator panel will reset the drive and possibly clear the error. If error persists, call Kval support.

Y Axis Servo Drive Fault The Y axis Servo Drive has a fault on it and has stopped operation. Check fuses on drive and replace, if needed. The RESET DRIVES button on the main operator panel will reset the drive and possibly clear the error. If error persists, call Kval support.

Air Level Low The air level is to low for normal operation.

Air Level Low Latch The air level was or is low.



6-5

Plunge Troubleshooting Screen


Setup Mode While in setup mode, the DL-NCB will operate normally except that it will not plunge into and cut the door. Setup mode can be turned on or off on the Manual Run screen on the Touch Screen (see page 3-4).

Collision Sensor The eye that checks for a collision with the movable fence is detecting the fence. This could result from either bad door parameters being downloaded or a malfunctioning eye.

Valid Download Received

A set of valid door parameters has not been downloaded. The machine has nothing to do.

Cutter Motor Warmup Complete

The cutter motor has not yet completed its warm-up cycle. The DL-NCB will wait until this process has completed before it will start cutting.

Cutter Motor Over-Temp The cutter motor over-temp signal is active. Wait for cutter motor to cool.

Clamped The DL-NCB has not clamped a door. A door must be clamped for the cutting cycle to start.

Download Received Machine is in idle mode. Check downloaded parameters.



6-6

Auto-Feed Troubleshooting Screen


Auto Feed Auto-Feed is not on. Turn on or off Auto-Feed mode on the Run Touchscreen (see page 2-16 for details on Feed Modes).

Auto Feed Disabled Disabled auto-feed button is active. There are two buttons, one on the Touchscreen and one on the main operator panel (optional).

Before Outfeed Stop Clear

An internal signal. Kval support personal will know the meaning of this signal.

Door Sense Eye Eye is detecting a door coming into the machine is not covered.

After Outfeed Eye The eye at the end of the machine that indicates that the last door is clear of the machine is covered. Remove covering to continue process.

Cutter Head Not Up The Cutter Head limit switch is not active, indicating that either the head is not fully retracted or the switch is bad. The most common reason for this error is that the air supply is off or low and so the head is not fully lifted.

Eject Retracted The eject cylinder eye is not activated, indicating that either the eject cylinder is not retracted or is not reading correctly.



6-7

Servos Troubleshooting Screen


Check Homing This button takes the user to the Homing Troubleshooting Screen. Issues with servo motors are often the same issues as the machine not homing.

X Axis Servo Drive Fault The X axis Servo Drive has a fault on it and has stopped operation. Check fuses on drive and replace, if needed. The RESET DRIVES button on the main operator panel will reset the drive and possibly clear the error. If error persists, call Kval support.

Y Axis Servo Drive Fault The Y axis Servo Drive has a fault on it and has stopped operation. Check fuses on drive and replace, if needed. The RESET DRIVES button on the main operator panel will reset the drive and possibly clear the error. If error persists, call Kval support.

Servo Reset CR An internal signal.

High Freq Drive Error One of the high frequency drives has an error. Check the drives in the high frequency electrical box (the smaller of the two electrical boxes) for errors or bad fuses.

Tool Changer Gate Open

The switch on the tool access gate is open. The gate needs to be closed for the DL-NCB to home.

Galil Servo Disable An internal signal. Kval support personal will know the meaning of this signal.

Any Crash Limit One or more crash switches are active.

Low Air The air level is to low for normal operation.

DataLink Error The I/O nodes on either the head or on the frame are not communicating correctly.



6-8

Warning Pop-up Screen There are certain error conditions that will cause this pop-up screen to display. To find the cause for the warning, look at the status indicator (“Check” indicates an error).


Servo Drive Fault One of the servo drives has a fault. Click the Troubleshoot Screens button and use the Servos Troubleshooting Screen to find the cause (see page 6-7).

AC Drive Fault Check the High Frequency Drives for fault conditions.

Cutter Over-Temp The cutter motor over-temp signal is active. Wait for the cutter motor to cool.

Cooling Air Level Machine air pressure is low. Check air supply. For adjustment, see diagram on page 5-3.

DataLink Comm Error The I/O nodes on either the head or on the frame are not communicating correctly. Go to the Main Menu and use the DLNCB I/O Status Screen to find the cause (see page 6-9).

Troubleshoot Screens Click this button to access the Troubleshooting screens (see page 6-2).



6-9

Using the Touch Screen’s Status Displays Below are descriptions of the status screens on the DL-NCB Touch Screen. Additional screens for troubleshooting are located on page 6-2.

DL-NCB Machine I/O Status Screens

Frame Status Screen


(photo detectors) The diagram below maps the display icons to the physical sensors on the machine. An icon is red when the sensor detects the presence of a door. Troubleshooting information on photo detectors is provided on page 6-20.

Clamp White = Clamp is released Green =Clamp is applying pressure

Infeed Stop White = In-feed stop is down Green = In-feed stop is up

Outfeed Stop White = Outfeed stop is down Green = Outfeed stop is up

See Galil I/O Status Screen (contact Kval Support for assistance)

See Frame Status Screen and Carriage Status Screen descriptions (page 6-9 & 6-11)



6-10


Feed Mode:

Fwd Red = Feed mode is set to forward Blue = Feed is not moving in the forward direction

Rev (reverse) Red = Feed mode is set to reverse Blue = Feed mode is not set to reverse

Slow (forward) Red = Feed mode is slow Blue = Feed mode is not slow

OK To Feed In = The DL-NCB is not signaling the previous machine to feed in a door.

= The DL-NCB is signaling the next machine to feed in a door.

OK To Feed Out = The next machine is not ready for the next door. = The next machine is ready for the next door.

MENU Return to Main Menu

Troubleshoot Menu Displays the Troubleshooting main menu (see page 6-2)

Carriage Status Displays the Carriage Status Screen (see page 6-11)

Locations of Photo Detectors and Feed Stops



6-11

Carriage Status Screen


Light Tower status:

Download (off) = Machine is not ready for work. (constant) = Machine is ready for work. (flashing) = Machine is ready for work, but has no program.

Cutter Running (off) = Cutter is off. (constant) = Cutter is on. (flashing) = Failure with any drive.

Any Limit Switch (off) = No fault found. (constant) = Machine not homed, any limit switch activated. (flashing) = Machine has been homed, limit switch activated.

DUST HOOD UP = Dust hood over the Cutter Head is not up. = Dust hood is up.

CUTTER UP = Cutter head is retracted. = Cutter head is not retracted.

SHALLOW = The cutting head is not in the shallow position. = The cutting head is in the shallow position.

Turn Cutter On = Cutter is Off. = Cutter is on.

Send Cutter Down = The cutting head is not in the fully extended position. = The cutting head is in the fully extended position.

OSC. = Tool Oscillation eye is not active. = Tool Oscillation eye is active.

DOWN = Cutter head is not fully extended. = Cutter head is fully extended.

EJECT EYE = Punch out is retracted. = Punch out is extended.

COLLISION EYE = Fence Collision Eye is not active. = Fence Collision Eye is active.

MENU Return to Main Menu

Troubleshoot Menu Displays the Troubleshooting main menu (see page 6-2)

Frame Status Displays the Frame Status Screen (see page 6-9)



6-12

Correcting Cut Accuracy Problems For full details on calibrating the cut accuracy, refer to the procedure on page 3-33.

Cut Accuracy Problems Description

Cut too low on Door using the outfeed end stop

Go to Calibration page 1 in the KVAL 2006 interface and locate Primary Stop-Outfeed (1).

• Enter a negative number by the amount it is off in the right hand box of Primary Stop-Outfeed (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.

Cut too high on Door using the outfeed end stop

• Enter a positive number by the amount it is off in the right hand box of Primary Stop-Outfeed (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.

Cut to low on Door using the in-feed end stop

Go to Calibration page 1 in the KVAL 2006 interface and locate Secondary Stop-Infeed (1).

• Enter a positive number by the amount it is off in the right hand box of Secondary Stop-Infeed (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.

Cut to high on Door using the in-feed end stop

• Enter a negative number by the amount it is off in the right hand box of Secondary Stop-Infeed (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.

Cut needs to be moved closure to the fixed fence

Go to Calibration page 1 in the KVAL 2006 interface and locate Y Calibration(1).

• Enter a negative number by the amount it is off in the right hand box of Y Calibration (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.

Cut needs to be moved away to the fixed fence

• Enter a positive number by the amount it is off in the right hand box of Y Calibration (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.



6-13

Troubleshooting the Air Cylinders Most cylinders have an extend and retract port. To adjust the extend motion of a cylinder you must adjust the flow control on the retract port; this regulates the air flow exhausting from the cylinder and the opposite is true for the retract motion.

1. Check the air pressure to the machine. 2. Check the flow controls to see that they are adjusted correctly and to the proper

specifications.

3. Check for any obstructions to the cylinders such as screws or a misplaced tool etc. FOLLOW

ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS. 4. Check the solenoid air valves:

a. The solenoid valves can be manually operated by pushing the red manual override button on the end of the valve.

CAUTION: Once activated, The valve will allow full pressure to cylinder. Make sure you are clear of all moving parts.

b. If the valve seems to be leaking, the seals may be dry or contaminated with water or it maybe that the cylinder “O” rings are damaged and air is passing from one side to the other side of the cylinder which means the air is exhausting through the solenoid valve. It maybe is necessary to purchase a rebuild kit or a new cylinder.

Manual over-ride button



6-14

c. If the valve is not receiving an electrical signal, see the electrical troubleshooting section on page 6-15 for instructions. It might be necessary to call in a specialist or check with KVAL customer service at 1-800-553-5825.

5. If an Air Leak is coming from an exhaust port on the solenoid air bank: a. Check the solenoid for the manual override. If the solenoid has a manual override

you can push each of the buttons one at a time. When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty.

Adjusting Cylinder Extension Speed:

Adjusting Cylinder Retraction Speed:



6-15

Troubleshooting Electrical Problems

THE FOLLOWING SHOULD ONLY BE ATTEMPTED BY TRAINED ELECTRICAL PERSONNEL.

The electrical component systems are designed to expedite the troubleshooting process and minimize “down time”. In general, component systems have the input or feed functions at the top. Output or load functions are positioned at the bottom. Most two-voltage electrical panels are designed with the LOW VOLTAGES on the LEFT, and the HIGH VOLTAGES on the RIGHT. The majority of the system components are labeled with numbers that correspond with the electrical prints included in the electrical box door.

Computer controlled machines have signals on the computer that light up when the input or output functions are energized, respectively. Computer controlled as well as non-computer controlled machines have white 120V control power terminal strips. This will indicate power supply from the respective circuits.

Idec controllers also have lights on them for the input and output functions. You can easily find out which circuits are failing by watching the lights turn on or off. Compare the lights on the IDEC controller to the electrical print to determine what systems are being affected.

If the Power Stops During Normal Operation 1. Check that the input power disconnect switch is not turned off. 2. Check that all of the emergency stop buttons are in the normal position. 3. Lock Out and Tag Out the main power source. 4. Turn the panel disconnect switch in the off position, open the electrical panel door. 5. Observe the disconnect switches. Look for loose or broken wires at the disconnect then at all

of the components. 6. Check for continuity of all fuses with an OHM meter. 7. Check motor overloads by pressing each white button (usually at the bottom of the panel) in

SEQUENCE,. If one is tripped there will be a slight resistance to touch and a “click” sound as it is reset.

WARNING The following checks require the electrical panel to be energized. These troubleshooting checks MUST BE PERFORMED BY A QUALIFIED ELECTRICAL TECHNICIAN.

1. Remove lock and tag outs on the main power sources. 2. Manually close disconnect switches and energize the control circuit or transformer with its

respective switch. Observe that the numbers 1, 3 & 4 are lit on the white lighted terminal strip. This tells you that there are no overloads or emergency stops tripped.

3. Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain, non tripped limit switches, etc.) The most common failure is an improperly adjusted limit switch. To check a limit switch, manually operate the limit switch. If the computer terminal strips lights, the switch needs to be re-adjusted. For more information on the limit switch specifications, see the manufacturer’s information. For limit switch adjustment procedures, refer to page 6-19.



6-16

4. If a solenoid valve is suspected, and not cleared in the air checks section (see page 6-8), it can be electrically jumped to check operation.

Troubleshooting with the Status Light Panel The Status List Panel is located on the front of the Operator’s Station, below the work surface area. It has six lights that are all illuminated when the system is in proper working order. If one or more lights are OFF, follow the process below to ascertain the cause.

NOTE: Be sure to proceed down the table, starting with the CONTROL POWER light.

Light If ON: If OFF:

CONTROL POWER

Go to OVERLOAD RELAY

• Check to see if the Control Transformer button is pulled out. • Is the Disconnect switch on the main electrical cabinet set to ON? • Is there 208, 220, 440, or 575 VAC to the top side of the Control

Transformer (E3)? If not, check the fuses at the Fuse Block (E5), and the contacts on the Control Transformer button on the switch panel.

• Is there 110 VAC between #1 & #2 on the110 VAC Terminal Strip? If not, check the fuse on the output side of the Control Transformer. If fuse is good, check power coming out of Control Transformer. 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.

OVERLOAD RELAY

Go to E-STOP

• There is No over-load relay on this machine. If there is power to the Status Light panel this light will be lit.

CONTROL POWER

OVERLOAD RELAY

E-STOP

STOP

START

24VDC



6-17


E-STOP Go to STOP • Check to see the E-Stop button(s) is pulled out.

NOTE: Location and quantity of E-Stop buttons varies depending on customer need. Typical locations for E-Stop buttons are near the Rear Access Gate and near the Tool Changer Access Gate

• For Single E-Stop button machines: Check for 110 VAC between #2 and #4. If no voltage, check to see if the E-Stop button is pulled out. If the E-Stop button is pulled out and E-Stop light is OFF check the wiring. If no fault is found in the wiring turn off the DL-NCB main power and check for continuity across the pulled out E-Stop switch.

• For multiple E-Stop Button machines: With on side of the meter on #2 check for 110 VAC on #4 through #5. If at any point no voltage is found trace the wires to find the associated E-Stop button and check to see if that button is pulled out. If the E-Stop button is pulled out and the E-Stop light is OFF check the wiring. If no fault is found in the wiring turn off the DL-NCB main power and check for continuity across the pulled out E-Stop switch.

• Check to see if the Back Gate is closed. • Check to see if the Disconnect switch on the high-frequency

electrical cabinet is ON. • Check for 110 VAC between #2 and #3A on the 110 VAC

Terminal Strip. If there is 110VAC, go to next step: If the Disconnect switch on the high-frequency electrical cabinet is OFF (closed) and there is not 110 VAC between #2 and 3A, check the wiring.

• Check for 110 VAC between #2 and #3B. If there is 110 VAC, go to next step: If the contact on the Rear Access Gate is closed and there is no power between #2 and #3B, check for wiring problems.

STOP Go to START

• Check for 110 VAC between #2 and #6. If there is voltage, press the 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.

START Go to 24VDC

• Push the Start button. If the Start light remains unlit, push in the Start button and hold it in while a second person checks for voltage between #2 and #7. If there is 110 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wiring.



6-18


24VDC Home the DL-NCB (see page 2-14)

Check between DC+ and DC- for 24VDC. If no DC voltage, disconnect the + Brown/Red and - Blue/Black wires from the 24VDC power supply and check for DC voltage where those wires were disconnected. If no voltage:

• Check the input side for 110 VAC. If no 110 VAC, check the fuse. If there is 110 VAC and no 24VDC, replace the 24VDC Power Supply.

If there is 24VDC: • Reconnect the + Brown/Red and - Blue/Black wires to the

24VDC power supply. • Trace the + Brown/Red wire to the DC terminal block. • Disconnect all brown wires from the + DC from the DC

terminal block except the + Brown/Red wire form the + 24VDC power supply.

• Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block.

• Reinstall the + brown wires one by one checking for +24VDC after installing each + brown wire. If at any point no voltage is found trace the last reinstalled wire and check for shorts.



6-19

Adjusting Limit Switches If a machine suddenly stops in mid cycle, check the limit switches. A worn limit switch arm or a misadjusted limit switch is more than likely the cause. (Another potential cause is faulty photo eyes – see page 6-20 for details.)

Depending on the model of limit switch on your machine, the pre-travel (amount of movement from the limit switch arm’s resting position to the position at which the switch actuates – with a “click”) is either 5 or 20 degrees. The DL-NCB has five limit switches that have 5 degrees of pre-travel (3 on the X axis and 2 on the Y axis), and two switches that have 20 degrees of pre-travel (on the Cutter head).

If the arm is moved to the full extent of its travel and you do not hear the limit switch “click”, the switch needs to be adjusted. Use the set screw on the limit switch arm and adjust the arm to activate at the desired degree of rotation (see illustrations below).

Examples of Limit Switches located on DL-NCB:

5° or 20°



6-20

Troubleshooting Photo Detectors Another cause of improper machine operation is a faulty or dirty photo detector.

There are two types of photo detectors on the DL-NCB: Through Beams and Photo Eyes.

• Through Beam Detectors consist of an emitter and detector. The emitter sends a light beam that is sensed by the detector. The detector then sends 0VDC to the PLC. If the beam is broken the detector sends 24VDC to the PLC.

• Photo Eye Detectors contain both emitter and receiver. If an object is within the Photo Eye’s sensing field light from the emitter is reflected from the object back to the receiver. The Photo Eye then sends 24VDC to PLC. If no object is sensed the Photo Eye sends a 0VDC to the PLC. As a result any of the DL-NCB photo detectors output 24VDC when a door is sensed.

If the photo detector is dirty, it will falsely sense the presence of a door, or other obstruction, and stop the machine operation. If a suspected Photo Detector is clean check for the proper DC Voltage.

If your machine is experiencing problems with the automatic fence width adjustment, check the five fence-width Photo Eyes at the in-feed end of the machine that look up from underneath the door. There is also one Photo Eye located at the out-feed end of the machine that looks up at the door from underneath.

If your machine is experiencing door feed problems, check the four Through Beams mounted on the fence that sense the door as it progress through the machine (see illustration below).

Emitter, located on fixed fence (4 units total)

Path of door (from in-feed to out-feed)

Detector, located on adjustable fence (4 units total)

Path of light beam



6-21

Getting Help from Kval Before you seek help, first try the troubleshooting procedures in Solutions to Common Problems on page 6-1. If you are still not able to resolve the problem, contact our customer support engineers:

• In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485 • Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485 • Email address is [email protected]

Technical Support business hours are 4:00 AM to 4:30 PM Pacific Standard Time, Monday through Friday.

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.

1. Obtain the packing slip and/or invoice numbers of the defective unit, and secure a purchase order number to cover repair costs in the event the unit is determined to be out of warranty.

2. Reason for return: Before you return the unit, have someone from your organization with a technical understanding of the DL-NCB system and its application include answers to the following questions: • What is the extent of the failure/reason for return? What are the relevant error messages

or error codes? • How long did it operate? • Did any other items fail at the same time? • What was happening when the unit failed (e.g., installing the unit, cycling power, starting

other equipment, etc.)? • How was the product configured (in detail)? • Which, if any, cables were modified and how? • With what equipment is the unit interfaced? • What was the application? • What was the system environment (temperature, spacing, contaminants, etc.)?

3. Call Kval customer support for a Return Material Authorization (RMA). When you call: • Have the packing slip or invoice numbers available. • Have the documented reason for return available.

4. Send the merchandise back to Kval. • Make sure the item(s) you are returning are securely packaged and well protected from

shipping damage • Include the packing slip or invoice numbers. • Include the documented reason for return. • Include the RMA number with the parts package.

p/n: M-DLNCB1 rev 1.0 February 27, 2006 xi This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

Index A

abort a cut in progress, 2-22 access gates

definition of, 2-4 adjustable fence

auto-adjust control, 2-10 manually open and close, 2-10

adjustable fence, definition of, 2-6 air cylinders, troubleshooting, 6-13 air filters, cleaning, 5-2 air line lubricator

adjustment, 5-3 priming, 5-3

air supply (psi), 5-3 auto-adjust enable/disable, 2-10 auto-feed mode, 2-9, 2-17

Disable Auto Feed button, 2-5 enable/disable, 2-10 troubleshooting (touchscreen), 6-6

B

back up system files, 4-1 barcode operation. Contact Kval Customer Service

for assistance bearings, lubricating, 5-2 bit. See tool bit oscillation, 2-9

C

calibration, 3-21 tool changer, 3-21

preparing for, 3-21 stage 1 (calibration bolt alignment), 3-23 stage 2 (tool holder offset), 3-27 stage 3 (tool holder adjustment), 3-31 which stage to use, 3-21

calibration bolt alignment, 3-23 calibratoin

cut accuracy, 3-33 call door foot pedal, 2-4, 2-17 canceling a cut in progress, 2-22 clamp door manually, 2-10 collet

assembly components, 3-19 definition of, 2-3 tool bit change, 3-19

compliance with codes and regulations, 1-3 contacting Kval. See inside front cover

control panel, 2-5 control transformer button, 2-5, 2-11, 2-12 coordinates (+ and –), 2-6 customer layout diagram, i customer service contact info. See inside front

cover cutter gantry, definition of, 2-3 cutting doors, 2-18. See Also Door Files

cut accuracy calibration, 3-33 cut accuracy problems, correcting, 6-12 templates. See templates

cutting speed select switch, 2-5

D

data backups, 4-1 data entry, KVAL 2006 user interface, 2-8 disable auto feed button, 2-5 disabling tool locations, 3-17 documentation

online/PDF document library, ii organization of this document, i related publications, i

door count, 3-6 door feed, slow speed, 2-10 door files

backing up, 4-1 creating

from existing door file, 3-14 from scratch, 3-13 temporary files, 2-19

deleting, 3-16 download status, 2-9, 2-10 modifying permanently, 3-15 override the door count, 2-22 restarting, 2-22 running/executing

canceling a cut in progress, 2-22 overview of options, 2-18 saved files, 2-21 temporary files, 2-19

door sensors. See photo detectors door size, auto-adjust to, 2-10 drawbar extension, checking & adjusting, 5-7 drive reset button, operator panel, 2-5, 6-4 drive reset buttons, high-frequency cabinet, 2-4

E

eject function, 2-9 electric eyes. See photo detectors


xii p/n: M-DLNCB1 rev 1.0 February 27, 2006 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

electrical problems, troubleshooting, 6-15 electrical schematics

troubleshooting with, 6-15 where to find them, i

email customer support. See inside front cover give us your feedback about product. See inside

front cover E-Stop

definition of switch, 2-4, 2-13 resume operation after E-Stop, 2-13

F

FAQs, 6-1 feed mode

selecting via Run screen, 2-9, 2-16 feed off mode, 2-9, 2-16 feed speed, of door, 2-10 feedback to Kval. See

[email protected] feed-thru mode, 2-9, 2-17 file backups, 4-1 fixed fence, 2-6 foot pedal, 2-4, 2-17 fractions, converted to decimal values, 2-8

G

glossary of terms, 2-2 grease points, 5-4

H

help, 6-21 hole cut templates, 3-8 homing, 2-14

home location, 2-6 procedure, 2-14 troubleshooting touchscreens, 6-3

I

I/O status carriage, 6-11 frame, 6-9 Galil I/O. Contact Kval Supppot

in-feed end of machine, 2-6 introduction to product, 1-1 IT administration, 4-1

J

jog the door in the machine, 2-10

K

knock-out function, 2-9 KVAL 2006 User Interface

description & tour, 2-7 entering data, 2-8 exiting, 2-22 keystroke shortcuts, 2-8

L

left-hand (LH) door, definition of, 2-6 library of system documentation, ii limit switches, adjusting, 6-19 lock out procedure, 1-4 lubrication requirements, 5-2

M

Machine Data (touchscreen) description, 3-6 maintenance, 5-1

cutter motor spindle, 5-6 lubrication requirements, 5-2 schedule, 5-1

manual feed mode, 2-9, 2-16 Manual Run (touchscreen) description, 2-10, 3-4 manually change tool, 3-18 manually clamp door, 2-10, 2-16 manually open/close door width fence, 2-10, 2-16 manually position door in machine, 2-10, 2-16 motor warmup status, 2-9, 3-5, 6-5

N

negative (–) direction, 2-6 null option (feed through door w/o making cuts),

2-17

O

ON-3, relative to DL-NCB, 1-2, 2-6 online PDF documentation library, ii opcodes for hold cuts, 3-8 operator's station description, 2-5 organization of this document, i orientation to axes and coordinates, 2-6 oscillation, bit, 2-9 out-feed end of machine, 2-6 override the door count, 2-22 overview of product, 1-1

tour of machine and software, 2-2

P

PDF documentation library, ii photo detectors

status, 6-9 troubleshooting, 6-20

Index


xiii

position door manually, 2-10, 2-16 positioning coordinates (+ and –), 2-6 positive (+) direction, 2-6 power

disconnect switches, 1-4 lock out procedure, 1-4 power down the machine, 2-12 power up the machine, 2-11 troubleshooting, 6-15, 6-16

pre-defined (saved) door files, 2-21 primary stop, 2-6

manually controlling, 2-10 product overview, 1-1 product return procedure, 6-21 proximity sensors. See photo detectors

R

reciprocating the cutting tool, 2-9 rectangular cut templates, 3-7 related publications, i reset drive button

control panel, 2-5, 6-4 reset drive buttons

high-frequency cabinet, 2-4 restarting a door file, 2-22 return material authorization (RMA), 6-21 returning the product to Kval, 6-21 reverse feed mode, 2-9, 2-17

reverse feed procedure, 2-17 right-hand (RH) door, definition of, 2-6 Run (touchscreen) description, 2-9, 3-3

S

safety cage guidelines for entering, 1-2

safety guidelines, 1-2 scanning the tool holders, 2-15 scheduled maintenance, 5-1 secondary stop, 2-6

manually controlling, 2-10 security lock mode, 2-9 sensors. See photo detectors setup mode, 2-10 shutoff valve, air, 5-3 slug knock-out function, 2-9 solutions to common problems, 6-1 special cut templates, 3-9 speed of door feed, 2-10 spindle maintenance, 5-6 start button, 2-5, 2-11, 2-13 status light panel, 2-5

lit on successful power-up, 2-11 troubleshooting with, 6-16

status touchscreens, 6-9

stop button, 2-5 stops

definition of, 2-6 manually controlling, 2-10

system architecture, 4-1 system documentation, ii

T

tag out guidelines, 1-5 technical support, 6-21

contact info. See inside front cover remote assistance, 4-1

templates, 3-6 creating/saving

hole cuts, 3-8 rectangular cuts, 3-7 special cuts, 3-9

deleting, 3-12 global vs. tenant, 3-15 modifying permanently, 3-11 modifying temporarily, 2-20

tool associate with door material, 2-9 bit replacement, 3-19 change manually, 3-18 clamping assembly maintenance, 5-9 definition of, 2-3 disable, 2-9 machine remembers last used tool, 3-17 oscillate/reciprocate, 2-9 spindle maintenance, 5-6 status, 3-5 tool scan during homing, 2-15

tool changer, 3-17 calibration. See calibration definition of, 2-3 operational description, 3-17 touchscreen description, 3-5

tool disable, 3-17 tool holder

calibration, 3-27, 3-31 disabling locations, 3-17

touchscreens advanced operation screens, 3-2 basic operation screens, 2-8 location on operator’s station, 2-5 screen descriptions

Carriage I/O Status, 6-11 DLNCB Warning pop-up, 6-8 Frame I/O Status, 6-9 Machine Data, 3-6 Manual Run, 2-10, 3-4 Run, 2-9, 3-3 Tool Changer, 3-5


xiv p/n: M-DLNCB1 rev 1.0 February 27, 2006 This page contains Kval, Inc. proprietary information and is not to be duplicated or disclosed to unauthorized persons.

Troubleshoot Auto Feed System, 6-6 Troubleshoot Homing, 6-3 Troubleshoot Plunge, 6-5 Troubleshoot Servos, 6-7

system status screens, 6-9 troubleshooting screens, 6-2

tour of KVAL 2006 user interface, 2-7 tour of machine, 2-2 tour of touchscreen interface, 2-8 Troubleshoot Auto Feed (touchscreen) description,

6-6 Troubleshoot Homing (touchscreen) description, 6-

3 Troubleshoot Plunge (touchscreen) description, 6-5 Troubleshoot Servos (touchscreen) description, 6-7 troubleshooting, 6-1 turning the machine on and off, 2-11

X

X axis + and - coordinates, 2-6 definition of, 2-6

Y

Y axis + and - coordinates, 2-6 definition of, 2-6

dl-ncb system reference · the dl-ncb computer-controlled door light cut-out machine is designed to...

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