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Innovation, Quality & Honesty

Operating InstructionsPublished: 9/24/08

Alliance Series

Introduction

IntroductionThis chapter provides a description of the Alliance Series product and identifies safety guidelines to ensure personnel safety and proper equipment use.

Overview of the Alliance Series

The Alliance System functions as a single door machine with multiple stations controlled from a central console. Integrated KVAL software tracks each door as it progresses, automatically setting up the next station just as the door arrives. This allows the Alliance to machine five different doors for five different specifications simultaneously; no setup time is required between doors. Average productivity is one minute door-to-door for hinges and cylin-drical or mortise locks:

• Squared hinges with screw holes.• Cylinder locks with screw holes.• Mortise locks with function holes.• Card locks.• Auto routing and squaring for vision panels.• Viewer holes.• T-Strikes.• Flush bolts including deep drills to 12”.• End detailing for closers, holders

Alliance Series a-a

a-b Alliance Series

Table of Contents

CHAPTER 1 ........................................................................ The Alliance Line 1-1Tour of the Line ............................................................................................... 1-3Quick Start ....................................................................................................... 1-4

How to load a door stack: .......................................................................... 1-6Typical Alliance Product flows .................................................................. 1-7

Single Stack Feed ................................................................................... 1-7Dual Stack Feed ...................................................................................... 1-7Single Door Feed .................................................................................... 1-8External processing ................................................................................. 1-8Removing Single Doors from the process flow ...................................... 1-9Stack Manipulation ................................................................................. 1-9

Mid-Cycle Shutdown and Recovery .............................................................. 1-11Causes of Mid-cycle shutdown ................................................................ 1-11Recovery from Mid-cycle shutdown ....................................................... 1-11

How to re-power a shutdown down machine: ...................................... 1-12How to Manually remove uncompleted doors from the line: ............... 1-14Manual Feed and Width control using the KVAL2006 Program .......... 1-18

CHAPTER 2 ...................................................The KVAL 2006 User Interface 2-1Launching the KVAL 2006 User Interface ............................................. 2-1KVAL 2006 User Interface Visual Tour ................................................ 2-1

Keystroke Shortcuts ................................................................................... 2-2Entering Data ............................................................................................. 2-2

CHAPTER 3 ......................................................................................ON-2010 3-1Door Stack Access ........................................................................................... 3-3

To Enable the Door Stack Access Mode: ............................................... 3-3To Disable the Door Stack Access Mode. .............................................. 3-4

ON-2010 - Operator’s Tour .............................................................................. 3-5Operators Station: ............................................................................................ 3-5

Control Panel ............................................................................................. 3-5Touch Screen .................................................................................................... 3-6

OK to Home ............................................................................................... 3-6Navigation & Control ............................................................................. 3-6

Main Menu REMOTE ............................................................................... 3-7Feed Mode .............................................................................................. 3-7Manual Feed: .......................................................................................... 3-7Door Data ................................................................................................ 3-8

Alliance Series

Stack Control: ....................................................................................... 3-10Navigation ............................................................................................. 3-10

Main Menu LOCAL ................................................................................ 3-11Running Data: ....................................................................................... 3-11Door Width Entry: ................................................................................ 3-12How to change a door width preset: ..................................................... 3-13Entering Fractional Values: ................................................................... 3-14Lift: Move and Mode Control ............................................................... 3-14Stack Control: ....................................................................................... 3-14Feed Mode ............................................................................................ 3-16Navigation ............................................................................................. 3-16Ready Enter Data .................................................................................. 3-16

How to Run a Door in Manual Local Mode: ........................................... 3-17Manual Mode ........................................................................................... 3-18

Reset Sequence: .................................................................................... 3-18Forklift Control: .................................................................................... 3-18Carriage Control: .................................................................................. 3-18Stack Control: ....................................................................................... 3-19Feed Mode: ........................................................................................... 3-19

Maintenance -1 ........................................................................................ 3-20Data: ...................................................................................................... 3-20Change Position: ................................................................................... 3-20Feed Mode ............................................................................................ 3-20Manual Feed: ........................................................................................ 3-20Navigation: ............................................................................................ 3-20

Maintenance -2 ........................................................................................ 3-21Touch Screen view adjustments: .......................................................... 3-21Navigation: ............................................................................................ 3-21

Machine Data ........................................................................................... 3-22Technical Support .................................................................................... 3-22

Homing the ON-2010 .................................................................................... 3-23To Home the ON-2010 ......................................................................... 3-23

CHAPTER 4 ............................................................ Calibrating the ON-2010 4-1

CHAPTER 5 ........................................................................................... FACE 5-1FACE - Operator’s Tour: .................................................................................. 5-3

Control Panel .......................................................................................... 5-3Cutting Head ........................................................................................... 5-4

Touch Screen .............................................................................................. 5-5Main Screen ............................................................................................ 5-5Manual Run Screen ................................................................................. 5-6

Homing the Face .............................................................................................. 5-7

Alliance Series

To Home the Face ................................................................................... 5-7Router Collets .................................................................................................. 5-9

Tool Insertion .......................................................................................... 5-9Collet Maintenance ................................................................................. 5-9

CHAPTER 6 ................................................................. Calibrating the FACE 6-1How to modify a Parameter: ............................................................................ 6-2Parameters ........................................................................................................ 6-4

Tool size and Cutting Depth ...................................................................... 6-4Top Main Router ..................................................................................... 6-4Top Router Depth .................................................................................... 6-4Bottom Main Router ............................................................................... 6-4Bottom Main Router Depth .................................................................... 6-4D1 Top .................................................................................................... 6-4D1 Top Depth .......................................................................................... 6-4D1 Bottom ............................................................................................... 6-5D1 Bottom Depth .................................................................................... 6-5D2 Top .................................................................................................... 6-5D2 Top Depth .......................................................................................... 6-5D2 Bottom ............................................................................................... 6-5D2 Bottom Depth .................................................................................... 6-5

Automated Tool Selection .......................................................................... 6-6D2 Neg .................................................................................................... 6-6D2 Pos ..................................................................................................... 6-6

Cut Location .............................................................................................. 6-7Top Main Router X ................................................................................. 6-7Top Router Y ........................................................................................... 6-7D1 X ........................................................................................................ 6-8D1 Y ........................................................................................................ 6-8D2 X ........................................................................................................ 6-9D2 Y ........................................................................................................ 6-9Left Hand X .......................................................................................... 6-10Right Hand X ........................................................................................ 6-10SSX1: .................................................................................................... 6-11SSX2: .................................................................................................... 6-11SSX3 ..................................................................................................... 6-11SSX4 ..................................................................................................... 6-11SSX5 ..................................................................................................... 6-11

Left Stop Calibrations .............................................................................. 6-12Left Stop 1 ............................................................................................. 6-12Left Stop 2 ............................................................................................. 6-12Left Stop 3 ............................................................................................. 6-13Left Stop 4 ............................................................................................. 6-13Left Stop 5 ............................................................................................ 6-14

Alliance Series

Left Stop 6 ............................................................................................ 6-14Left Stop 7 ............................................................................................ 6-15Left Stop 8 ............................................................................................ 6-15Left Stop 9 ............................................................................................ 6-16Left Stop 10 .......................................................................................... 6-16Left Stop 11 .......................................................................................... 6-17

Right Stop Calibrations ............................................................................ 6-18Right Stop 1 .......................................................................................... 6-18Right Stop 2 .......................................................................................... 6-18Right Stop 3 .......................................................................................... 6-19Right Stop 4 .......................................................................................... 6-19Right Stop 5 .......................................................................................... 6-20Right Stop 6 .......................................................................................... 6-20Right Stop 7 .......................................................................................... 6-21Right Stop 8 .......................................................................................... 6-21Right Stop 9 .......................................................................................... 6-22Right Stop 10 ........................................................................................ 6-22Right Stop 11 ........................................................................................ 6-23

CHAPTER 7 ......................................................................... Architect DI-DM 7-1Architect DI-DM - Operator’s Tour 7................................................................. -3

Control Panel: ......................................................................................... 7-3Touch Screen .................................................................................................... 7-4

Main Screen ............................................................................................... 7-4Feed Select .............................................................................................. 7-4Back Section Speed ................................................................................ 7-4Hinge Speed ............................................................................................ 7-4Navigation ............................................................................................... 7-4

Manual Run Screen .................................................................................... 7-5Manual Feed ........................................................................................... 7-5Navigation ............................................................................................... 7-5

Machine Data Screen ................................................................................. 7-6Homing the Architect DI DM .......................................................................... 7-7

To Home the Architect DI DM ............................................................... 7-7Router Collets .................................................................................................. 7-9


CHAPTER 8 ................................................Calibrating the Architect DI-DM 8-1How to modify a Parameter: ............................................................................ 8-2Parameters ........................................................................................................ 8-4

Front Section .............................................................................................. 8-4

Alliance Series

Pocket Definitions ................................................................................... 8-4Hinge Locations ...................................................................................... 8-4

Full Front section Calibration Procedure ................................................... 8-4Pocket Parameters - Predrills .................................................................. 8-5Pocket Parameters - General ................................................................... 8-5Router Diameter ..................................................................................... 8-6

General Front Section: ............................................................................... 8-6HINGE Z Each Pass ............................................................................... 8-6Hinge Outfeed Stop ................................................................................. 8-6Hinge Infeed Stop: .................................................................................. 8-6

Back Section .................................................................................................... 8-7Router ......................................................................................................... 8-7

Router Horizontal, Vertical ..................................................................... 8-7Router Diameter ...................................................................................... 8-7Router Depth ........................................................................................... 8-83 Deg Depth ............................................................................................ 8-8Z Each Pass: ............................................................................................ 8-8

Chisels ........................................................................................................ 8-8Z Offset to Chisel aa ............................................................................... 8-8Deep Mortis ............................................................................................ 8-9DM Diameter .......................................................................................... 8-9Z Ech DM Pass: ...................................................................................... 8-9DM Depth: .............................................................................................. 8-9

Counter Rotating Router .......................................................................... 8-10Cnt Rout Diam (Counter Router Diameter) .......................................... 8-10Cnt Rout Depth: .................................................................................... 8-10

Side Drills ................................................................................................ 8-11Side Drill Z: .......................................................................................... 8-11Side Drill Diam: .................................................................................... 8-11

General Back Section ..................................................................................... 8-12Side Enc. 0 ............................................................................................ 8-12Side Enc. 3DEG .................................................................................... 8-13

How to select a perfectly square door (or one that’s close enough) ........ 8-14Feed System ................................................................................................... 8-15

Infeed RH End check: ........................................................................... 8-15Outfeed LH End check: ........................................................................ 8-16Infeed Stop: ........................................................................................... 8-16

CHAPTER 9 ..........................................................................................EDGE 9-1EDGE - Operator’s Tour ......................................................................... 9-3Control Panel One ................................................................................... 9-4Control Panel Two .................................................................................. 9-5

Homing the EDGE ........................................................................................... 9-7

Alliance Series

To Home the EDGE ................................................................................ 9-7Deep Mortise Collet ......................................................................................... 9-9


CHAPTER 10 ............................................................ Calibrating the EDGE 10-1How to modify a Parameter: .......................................................................... 10-2Parameters ...................................................................................................... 10-4

Lock Location .......................................................................................... 10-4Lock Location RH ................................................................................ 10-4Loch Location LH ................................................................................. 10-4

Stops ......................................................................................................... 10-5Left Stop ................................................................................................ 10-5Middle Stop ........................................................................................... 10-5Right Stop ............................................................................................. 10-6 Left Outboard Stop .............................................................................. 10-6 Right Outboard Stop ............................................................................ 10-7

Deep mortise ............................................................................................ 10-7DM Vertical ........................................................................................... 10-7DM Diameter ........................................................................................ 10-8Deep Mortise X: .................................................................................... 10-8Depth parameters .................................................................................. 10-8

Plate Router .............................................................................................. 10-9Router Vert Offset (Vertical Offset) ...................................................... 10-9Router Diam (Diameter) ....................................................................... 10-9Depth parameters .................................................................................. 10-9

Counter Rotating Router ........................................................................ 10-10Cnt Rout Vert, Cnt Rout Horiz (Vertical, Horizontal) ........................ 10-10Cnt Rout Diam (Counter Router Diameter) ........................................ 10-10

Side Drills .............................................................................................. 10-11Chisels .................................................................................................... 10-11Predrills .................................................................................................. 10-12

Predrill 1 X offset and Predrill 1 vert offset ........................................ 10-12Depth parameter .................................................................................. 10-12

CHAPTER 11 .................................................................................. DL-NCC 11-1DLNCC - Operator’s Tour ............................................................................. 11-3Operators Station: .......................................................................................... 11-3

Power ....................................................................................................... 11-3Touch Screen .................................................................................................. 11-4

Main Screen ............................................................................................. 11-4Feed ...................................................................................................... 11-4

Alliance Series

Automatic Tool Changer .......................................................................... 11-5Tool Management ................................................................................. 11-6Status indicators: ................................................................................... 11-7Control: ................................................................................................. 11-7Navigation ............................................................................................. 11-7

Tool Changer ............................................................................................ 11-8Motor Status .......................................................................................... 11-8Tool Changer Status .............................................................................. 11-9Navigation ............................................................................................. 11-9

Manual Run ............................................................................................ 11-10Feed Controls ...................................................................................... 11-10Navigation ............................................................................................11-11

Changing a Tool Manually ..................................................................... 11-13To Change a Tool Manually ................................................................ 11-13

Changing a Tool Bit ............................................................................... 11-14To Change a Tool Bit .......................................................................... 11-14

Homing the DLNCC .................................................................................... 11-17To Home the DLNCC ......................................................................... 11-17

CHAPTER 12 .........................................................Calibrating the DL-NCC 12-1Calibrating the DL-NCC Tool Changer ................................................... 12-1

Determining Which Calibration Stage to Use ...................................... 12-1Preparing to Calibrate the Tool Changer .............................................. 12-1

Tool Calibration, Stage 1: Calibration Bolt ............................................. 12-3Tool Calibration, Stage 2: Tool Offset ..................................................... 12-8Tool Calibration, Stage 3: Tool Holders ................................................ 12-12Calibrating Cut Accuracy ...................................................................... 12-14

To Calibrate the Cut Accuracy ............................................................ 12-14Correcting Cut Accuracy Problems ....................................................... 12-17

CHAPTER 13 ........................................................................................ RAIL 13-1Door Stack Access ......................................................................................... 13-3

To Enable the Door Stack Access Mode: ............................................. 13-3To Disable the Door Stack Access Mode. ............................................ 13-4

Rail - Operator’s Tour .................................................................................... 13-5Operators Station: .......................................................................................... 13-6

Control Panel ........................................................................................... 13-6Touch Screen .................................................................................................. 13-7

OK to Home ............................................................................................. 13-7Navigation & Control ........................................................................... 13-7

Main Menu REMOTE ............................................................................. 13-8Feed Control ......................................................................................... 13-8

Alliance Series

Stack Control ........................................................................................ 13-8Navigation ............................................................................................. 13-9

Main Menu LOCAL .............................................................................. 13-10Door Length Entry .............................................................................. 13-10How to change a door length preset: .................................................. 13-11Entering Fractional Values: ................................................................. 13-12Feed Control ....................................................................................... 13-12Stack Control ...................................................................................... 13-12Navigation ........................................................................................... 13-13Ready Enter Data ................................................................................ 13-13

How to Run a Door in Manual Local Mode: ......................................... 13-14Manual Mode ......................................................................................... 13-15

Reset Sequence: .................................................................................. 13-15Forklift Servo: ..................................................................................... 13-15Stop Servo: .......................................................................................... 13-15Carriage Servo: ................................................................................... 13-16Stack Control ...................................................................................... 13-16Feed ..................................................................................................... 13-16Navigation: .......................................................................................... 13-17

Maintenance -1 ...................................................................................... 13-18Servo Position Points: ......................................................................... 13-18ModBus Communication mode: ......................................................... 13-18ModBus Communicating Status: Lift to Rail ..................................... 13-18Touch Screen Program Version .......................................................... 13-18Navigation ........................................................................................... 13-19Troubleshooting .................................................................................. 13-19

Maintenance -2 ...................................................................................... 13-19Touch Screen view adjustments: ........................................................ 13-19Navigation: .......................................................................................... 13-19

Remove Door ......................................................................................... 13-20Feed ..................................................................................................... 13-20 Cross feed system. ............................................................................. 13-20Clamp: Manual Operation .................................................................. 13-21Homing Status and Start Button ......................................................... 13-21Stack Control ...................................................................................... 13-21Reset Sequence: .................................................................................. 13-21

Machine Data ......................................................................................... 13-22Technical Support .................................................................................. 13-22

Homing the RAIL ........................................................................................ 13-23To Home the Rail ................................................................................ 13-23

CHAPTER 14 ...............................................................Calibrating the RAIL 14-1

Alliance Series

CHAPTER 1 The Alliance Line

This chapter provides over all operating instructions for the KVAL Alliance Line.

Alliance Series 1-1

The Alliance Line

1-2 Alliance Series

Tour of the Line

ON-2010

Lift, Flip and Rotate and Stack.

See “ON-2010” on page 3-1 for operating instructions.

FACE

For small complex cuts on a door’s face.

See “FACE” on page 5-1 for operating instructions.

Architect DI-DM

For small complex cuts on the hinge and lock edge of the door.

See “Architect DI-DM” on page 7-1 for operating instructions.

EDGE

For small complex cuts on the lock edge of the door.

See “EDGE” on page 9-1 for operating instructions.

DL-NCC

For large and small complex cuts on a door’s face.

See “DL-NCC” on page 11-1 for oper-ating instructions.

RAIL

For small complex cuts on a door’s top and bottom edge. plus a stacker.

See “RAIL” on page 13-1 for operating instructions.

Tour of the Line

Alliance Series 1-3

Quick Start1.Apply power to the Line.

a.Turn on all compressed lines to all machines.b.Turn on all electrical disconnects for all machines.c.Apply electrical power to all Safety Zones starting with Safety Zone one.

Note: Safety Zones must be turned on in order.

Safety Zone 1

Safety Zone 2

Safety Zone 3

Safety Zone 4

d. Pull out the CONTROL TRANSFORMER switch for each machine in the safety zone.

Each control transformer button should light and each computer should start.

e. Push the START button for each com-puter in the safety zone.

All lights on the Status Light Panel for each machine should be illuminated.

f. If all Safety Zones are powered the Power to the Line process is complete, if not move to the next safety zone and go back to step d.

ControlTransformer

Machine

START

STOP

CONTROL POWER

OVERLOAD RELAY

E-STOP

STOP

START

24VDC

1-4 Alliance Series

Quick Start

2. Launch the KVAL 2006 user interfaceFor each machine:

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

3. Home each machine:a. Remove any doors from the feed system.b. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.c. Click twice on the Home button. The machine should start the homing operation. d.NOTE:While the homing operation is in progress, the Home button changes its label to Homing.

4.

Network Off Network On

On each machine toggle the Network ON/OFF button to ON.

The Alliance line is now ready for work.

Maint

Home

OK

Homing

Home?

Alliance Series 1-5

How to load a door stack:

Top View

Door

Stack 1

Stack 2

Stop DoorStop

DoorStop Door

Stop

When loading Doorsmove doors into themachine all the way to the Door Stops.

When loading Doorsmove doors into themachine all the way to the Door Stops.

Feed

To load doors into the Alliance line:1. Chose the Door Stack 1 or Door Stack 2 to load based on product flow.2.Lower the Stack Lift to the desired height. See “Stack Control:” on page 3-10 for more information.3.Enable the Stack Access mode. See “Door Stack Access” on page 3-3 for more information.4.Load the doors onto the stack lift. Move the doors into the machine until they doors contact the door

stops.5.Disable the Stack Access mode. See “Door Stack Access” on page 3-3 for more information.

The doors are now ready to process.

1-6 Alliance Series

Quick Start

Typical Alliance Product flows

Single Stack Feed

Load DoorsHere

Remove DoorsHere

Use this mode to process a single door stack.

Dual Stack Feed

Load DoorsHere

Remove DoorsHere

HereLoad Doors

Use this mode to process two door stacks.

Alliance Series 1-7

Single Door

Load DoorsHere

Remove DoorsHere

Feed

This mode is typically used for template testing, or for re-processing a door after a a mid-process stream failure.

External processing

Remove Completed Doors Here

ExternalProcess

Normal Process Flow

This mode is used for a door that requires additional processing external to the Alliance line.

1-8 Alliance Series

Quick Start

Removing Single Doors from the process flowRemove Reject

Doors Here

Normal Process Flow

This mode is typically used to remove rejected doors from the process flow.

Stack Manipulation Remove Doors Here

Load Doors

This mode is used for reorienting doors within a door stack Any door in a stack can be flipped, rotated or both.

Alliance Series 1-9

1-10 Alliance Series

Mid-Cycle Shutdown and Recovery

Mid-Cycle Shutdown and RecoveryCauses of Mid-cycle shutdown

Mid-cycle shut down will result if any machine in the line loses power. Possible reasons for a machine can lose power can if:

• An E-Stop is pushed.• A Safety Gate is opened• An active Light Curtain is penetrated.• A Control Transformer button is pushed.• An Electrical Disconnected is turned off.• There is a Power Failure.

Recovery from Mid-cycle shutdown

When a mid-cycle shut down occurs, all door data information stored in the powered down machine is lost. To reload the door data all doors must be cleared from the line. To clear doors from the line:1.Allow the doors in the line past the shutdown machine can continue processing and be removed using

the normal process flow. 2.Re-power the shut down machine. See “How to re-power a shutdown down machine:” on page 1-12

for more details.3.Doors in the line before and in the shutdown machine must be revers fed back through the line and

removed from the infeed end of the ON-2010. See “How to Manually remove uncompleted doors from the line:” on page 1-14 for more details.

The example below shows the process flow if the Edge machine was shutdown.

Let the working machines continue processing. Remove completed Doors Here.

Manually remove uncompleted Doors Here

powered downEdge machine

ON-2010 FACE Arch-DI-DM EDGE DL-NCC RAIL

Alliance Series 1-11

How to re-power a shutdown down machine:

Determine the shut-down cause. Check the Status Light Panel located on the machines opera-tor’s station.

1.If the Control Power light is off: There is no power to the machine.Possible causes: An open disconnect, a blown fuse in the main power line, a tripped circuit breaker external to the machine.Action: Insure the disconnect is ON. If the Control Power light remains off, call the plant maintenance department.

2.If the Overload Relay light is off: Possible cause: A tripped overload relay in one of the machines electrical cabinets.Action: Call the plant maintenance department.

3.If the E-Stop light is off: Possible cause: An E-Stop has been pushed or safety gate is open.Action: Insure all E-Stops are pulled out, and safety gates are closed. If the E-Stop light remains off, call the plant mainte-nance department.Note: Within each safety area all E-Stops must be pulled out and all safety gates must be closed before any machine located in that safety will power up. Safety areas shown at right.

4.If the Stop light is off: Possible cause: The Control Transformer button was pushed in, momentary line power loss, low line power. Action: Insure the Control Transformer button is pulled out. If the Stop light remains off, call the plant maintenance depart-ment. Note: Within each safety area all Control Transformer buttons must be pulled out before any machine located in that safety will power up. Safety areas shown at right.

5.If the Start light is off:Possible cause: The Control Transformer button was pushed in, momentary line power loss, low line power. Action: Push the START button for each computer in the safety zone. If the Start light remains off, call the plant mainte-nance department.

Safety Zone 1

Safety Zone 2

Safety Zone 3

Safety Zone 4

CONTROL POWER

OVERLOAD RELAY

E-STOP

STOP

START

24VDC

Status Panel Lights



6.Enable the servos by starting the homing process:e.

Maint

Home

OKHome?

In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.f.Click twice on the Home button. The machine should attempt to start the homing operation. Since there is a door in the machine the homing process will abort. Use the mouse to click in the message box to clear the message.

Door in machine. Please remove door before homing

[Click to Clear]

ClickHere

The servos are now enabled. This will allow the machine to respond to the Jog commands.7.After the door is removed from the machine complete the homing process.

a. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.b. Click the Home button. This will change the button label to OK to Home?c.CLick the OK to Home? button.d.NOTE:While the homing operation is in progress, the Home button changes its label to Homing.

Maint

Home

OKHome?

Homing


How to Manually remove uncompleted doors from the line:

Manually remove uncompleted doors Here

ON-2010 FACE Arch-DI-DM EDGE DL-NCC RAIL

InfeedEnd

When reverse feeding doors through the line both width adjust and feed control must be done manu-ally. Note: Doors of the same width can be reverse as a group.

1. Door out:

Remove DoorHere

ON-2010

a.Reverse feed the door out of the ON-2010’s infeed end.From the main menu select Maintenance. Use the Jog Reverse to reverse feed the door.

b.If all the doors are removed from the line, this process is completed. If not go to the next step.Note: There is no support for the door at the infeed end of the line. Use a roll table or get help.

2. Move the door from FACE to ON-2010:ON-2010 FACE

a.Reverse feed the door from the FACE machine into the ON-2010. See “Manual Feed and Width control using the KVAL2006 Program” on page 1-18 for more information.a.Go to step 1.

Manual Run

JOGREVERSE



3. Move the door from 3rd machine to 2nd machine:FACE Arch-DI-DM

a. Adjust the FACE machine’s width adjust system to accommodate the door in the Arch_DI-DM. See “Manual Feed and Width control using the KVAL2006 Program” on page 1-18 for information.

b.Reverse feed the door from the Arch_DI-DM into the FACE.From the main menu select Maintenance. Use the Jog Reverse to reverse feed the door.

c.Go to step 2.

4. Move the door from EDGE machine to Arch_DI-DM:Arch-DI-DM EDGE

a. Adjust the Arch_DI-DM’s width adjust system to accommodate the door in the EDGE. See “Manual Feed and Width control using the KVAL2006 Program” on page 1-18 for information.

b.Reverse feed the door from the EDGE machine into the Arch_DI-DM. On the Main control panel press the Feed Reverse button.

c.Go to step 3.

5. Move the door from 5th machine to 4th machine:EDGE DL-NCC

a. Adjust the EDGE’s width adjust system to accommodate the door in the DL-NCC.b. The DL-NCC’s clamping mechanism, unlike the other machines in the line, is completely servo controlled. If the door is clamped the width adjust may need to be opened slightly to unclamp the door.

c.Reverse feed the door from the DL-NCC machine into the EDGE. From the main menu select Maintenance. Use the Jog Reverse to reverse feed the door.

d.Go to step 4.

Manual Run

JOGREVERSE

REVERSE

Manual Run

JOGREVERSE


6. Determine the path for the door in the RAIL:

• If the door is on the rollers see “Move the door from the Rail to the DL-NCC” below.• If the door is on the cross feed system see “Feeding a door in the Rail to stack #2” below.

Move the door from the Rail to the DL-NCC:DL-NCC RAIL

a. Adjust the 5th machine’s width adjust system to accommodate the door in the 6th machine.

b.Reverse feed the door from the 6th machine into the 5th machine.From the main menu select Maintenance. Use the Jog Reverse to reverse feed the door.

c.Go to step 5.

Feeding a door in the Rail to stack #2.

Stack #1

Stack #2

Cross FeedArea

a.In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.b.Click twice on the Home button. The machine should attempt to start the homing operation. Since there is a door in the machine the homing process will abort. Use the mouse to click in the message box to clear the message.

Door in machine. Please remove door before homing

[Click to Clear]

ClickHere

The Touch Screen button at the lower left portion of the screen should display Door Not in Position.

Manual Run

JOGREVERSE

Maint

Home

OKHome?

DOOR NOTIN POSITION



c.MANUAL

CROSSFEEDFORWARD

Move the door into the End Mill section of the machine using the Manual Crossfeed Forward button on the touch screen. The door must contact the End Mill Door Stop.

End Mill

End Mill

Door Stop

d.OK TO HOME

Press the OK to HOME Touch Screen but-ton at the lower left portion of the screen should display.

The machine should home. When homing is complete the machine will move the door to Stack #2 for removal.The machine is now ready for work.


Manual Feed and Width control using the KVAL2006 Program

The first page or pages of the calibration menu display the manual servo jog screens. To get to these screens:

a.On the PC, in the KVAL 2006 interface, click once on the Maint button.b.Click the CAL button.

A message pop up in front of the graphic display area.

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

X

X Axis Y Axis Z Axis

Jog X Y and Z

< > < > < >STOP STOP STOP

4000 4000 4000

EXIT

Setup

Calibration

Galil

C:\ \Dataline\Door.dbf\Dataline\Lock.dbf\Dataline\DoorNum.dbf\Dataline\LockDlnc.dbf\Doorlite\DLNC2004.cal\Doorlite\DLNCHome.cal

[Space Bar to Stop]

Calibration Menu

Width

< >STOP

4000

Change Axis

Typical Jog Menu

Change Menu Page

Exit the JogMenu

Axis JogControls

d.Change Axis Use the Change Axis button to find the desired Axis.Face: Width and FeedAll others: Width

e.

Width

< >STOP

4000

Stop

Axis Jog Control

Speed

Start Move(Close)

Start Move(Open)

Move

Example

Speed Adjust(Reduce)

Speed AdjustIncrease

Indicator

Use the Axis Jog Control to move the axis to the desired position.f.Use the Exit button to return to the main menu.

How to use the Axis Jog Control:a.Use Speed Adjust controls to adjust the servo speed to a workable rate.

Note: 4000 is a reasonable place to start.b.Use the Start Move and Stop Move buttons to move the servo axis to the desired location.c.Note: A Start Move button will start a axis in motion. The axis motion will continue until a Stop Move button is clicked.

Maint

Cal

Cal OK?

Calibration and Jog will Abort Program

Hit Esc or exit to cancel


CHAPTER 2 The KVAL 2006 User Interface

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

Launching the KVAL 2006 User Interface

On the Operator's Station computer, the KVAL 2006 user interface, in addition to other system adminis-tration 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 and cutting doors.

Click this button to finish processing the current door, but clear all subsequent door files.

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

To Home the machine, click “Maint” once, then click the but-ton below it (“Home”).

To enter Calibration mode () click “Maint” twice

These buttons are used to cancel a cut in pro-cess.

These buttons are used while defining or modify-ing door files or cut tem-plates.

Displays either:

• Door files that can be downloaded & run.

• Cut templates that can be assigned to a door file.

• List of templates as assigned to a spe-cific door file.

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

ViewField

Alliance Series 2-1

The KVAL 2006 User Interface

Keystroke Shortcuts

TABLE 1.

Keystroke Shortcut DescriptionF1 Abort - Stops the downloaded door file from being executed by the Alliance

Series.

Ctrl+F1 Key list - Displays this list

F2 Restart

F4 Barcode Off-On

F8 Download or put on list

F9 Door List Off-On

F10 Esc or Exit

F11 Program Off-On

F6+PROG PROG Copy.dbf

Ctrl+F12 Minimize Screen

F7 Full or Partial Download

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 equiva-

lent. 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.

2-2 Alliance Series

CHAPTER 3 ON-2010

This chapter provides operating instructions for the KVAL ON-2010.

Alliance Series 3-1

ON-2010

3-2 Alliance Series

Door Stack Access

Door Stack AccessThis ON-2010 is equipped with Light Curtain safety devices. Breaking the light curtain beam has the same result as pushing an E-Stop. Power is removed from all motors, all servo systems, and all control circuits. When enabled, the Light Curtains do not allow access to the door stacks. To enable access to the door stacks use the Door Stack Access Mode procedure shown below.

To Enable the Door Stack Access Mode:

Light Curtain

Stack Access Area

Light Curtain

Stack Access Area

(RED) (RED)

(YELLOW) (YELLOW)

1.Press the Enable Access button.2.Wait for the Enable Access button and the blue light tower light to flash on and off.3.The Stack Area is available for access.

With Safety Skirt, Entry OK No Safety Skirt, No Entry

CAUTION: At this point there is still power to all motion control systems. • Do not enter the machine any further than the

stack access area indicated in yellow above.• Keep away from the door lift and the vacuum

clamp.• The lift must be equipped with a safety skirt. Do

not enter the stack access area if the safety skirt has been removed.

CAUTION: The Door Stack Access Mode allows access behind the machine’s light curtain safety devices and is for loading and unloading the door stacks ONLY. No maintenance should be performed in this mode. All controlling outputs are frozen. However, POWER IS STILL APPLIED TO ALL MOTION CONTROL SYSTEMS. In this mode a system failure could cause a motion control system to “run away” at full speed. DO NOT PUT YOURSELF IN A MOTION CONTROL SYSTEM’S PATH.

USE EXTREME CAUTION WHEN enabling the Door Stack Access Mode.

Alliance Series 3-3

To Disable the Door Stack Access Mode.

1.Ensure all personal are away from the machine and outside the light curtain.1.Pull out the Enable Access button.

The Enable Access button and the blue light tower light should turn off.The machine is now ready to resume work.

3-4 Alliance Series

ON-2010 - Operator’s Tour

ON-2010 - Operator’s TourInfeed End

Outfeed End

FeedDirection

Top View

Door Lift Door Lift

Stack #1 Stack #2

Rollers

Carriage and Vacuum Clamp

Forklift(Lifts door form rollers)

Operators Station:Control

TransformerStart Machine

START

STOP

Disable LiftVacuumONOFF

Control Panel

• Control Transformer: Applies electrical power to control circuits and computer• Machine START / STOP: Applies electrical power to drive circuits.• Disable Lift: Stops the current process with two exceptions:

a. A “rotate will continue until the rotation is completed.b. A “Flip” will continue until the flip is complete.

• Vacuum: Controls the Vacuum Clamp’s vacuum.

Alliance Series - ON-2010 3-5

Touch ScreenOK to Home

Green ifHoming completed

123.45

MANUAL MODE

page 3-18

FORKLIFT

00:NOT HOMED

O.K. TO HOME

I-40CARRIAGE

00: NO ERROR

00:NOT HOMED00: NO ERROR

I-41

123.45

RDY

RDY

Forklift StatusMessages

Carriage StatusMessages

Position

Indicators

Navigation & Control

• Manual Mode: Opens the Manual Mode screen. See page 3-18 for more details.• O.K. to Home: Starts the homing process.

The OK to Home button has three states:Yellow = OK to HomeRed = Unable to home. The ON2010 has found a condition that prohibits it from homing. Green = Homed.

3-6 Alliance Series

Touch Screen

Main Menu REMOTE

MAINTE-NANCE

page 3-20

GO TO LOCAL

page 3-11

READY

NEW DOOR DATA RUNNING DATA

OK TO FEED-IN

STACK#1

MB: OK

123.45-12.34

NO ACCESS

I-14

PICK-UP

LOAD POS

FLIP ROT STACK#1 XFERSTACK#2FLIP ROT XFER

123.45-12.34

SLOW JOGFORWARD

JOGREVERSE

AUTOFEED

FEEDTHRU

MANUALFEED

STACK#2PICK-UP

LOAD POS

Door

Stack

Navigation

Data

Control

FeedMode

ManualFeed

The Main Menu REMOTE screen allows control of the machine from data received from a remote computer.

Feed Mode

MANUALFEED

AUTOFEED

FEEDTHRU

• Manual Feed: Puts the feed system in manual mode. In the manual mode the feed system is con-trolled by the Manual Feed buttons described below.

• Auto Feed: Puts the feed system in Automatic mode. In this mode the feed system is controlled by the machine’s computer.

• Feed through: In this mode the door will move through the machine without being processed.

Manual Feed:

SLOW JOGFORWARD

JOGREVERSE

• Jog Rev (Jog Reverse): Turns on the feed system in reverse mode if the Feed Mode is set to manual.• Slow: This button when pressed with either Jog Rev or Jog Fwd puts the feed system in slow mode.• Jog Fwd (Jog Forward): Turns on the feed system in reverse mode if the Feed Mode is set to man-

ual.


Door Data

READY123.45-12.34

FLIP ROT XFERFLIP ROT STACK#1 XFERSTACK#2

123.45-12.34

NEW DOOR DATA RUNNING DATA

FLIP ROT

Door Length

Door ManipulationIndicators Active Stack

IndicatorsOperation Mode

Indicator

Door Width

Data Transfer

Data for Next Door to be Processed Data for Door in Process

This portion of the display show door data for the door currently being processed, called Running Data, and door data for the next door to be processed, called New Door Data.

• Door Width and Door Length:Displays the programmed door width and door width values.

Door Length

DoorWidth Door

• Door Manipulation Indicators: The Door Manipulation indicators, Flip and Rotate, indicate how the machine will orient the door before the door leaves the machine. The four possible states are shown below.

Flip OFF, Rotate OFF:

No manipulation.

FLIP

LatchSide

HingeSide

Top

Bottom

ROT

Flip ON, Rotate OFF:

The door is flipped on it’s long axis.

FLIP

LatchSide

HingeSide

Top

Bottom

LatchSide

HingeSide

Top

BottomBefore Flip After Flip

ROT

Flip OFF, Rotate ON:

The door is rotated on it’s short axis.

LatchSide

HingeSide

Top

Bottom

LatchSide

HingeSide

Top

BottomBefore Rotate After Rotate

ROTFLIP

Flip ON, Rotate ON:

The door is flipped on it’s long axis, rotated on it’s short axis.

LatchSide

HingeSide

Top

BottomBefore Flip & Rotate After Flip & Rotate

LatchSide

HingeSide

Top

Bottom

FLIP ROT

• Active Stack Indicators: STACK#1STACK#2

3-8 Alliance Series

Touch Screen

Indicates the active door stack. The active stack will be shown as GreenInfeed End

Outfeed End

Stack #1 Stack #2

• Operation Mode Indicator: XFER XFER

The Transfer button (XFER) determines the product flow path. With Transfer OFF the doors flow from Door Stack 1, or Door Stack 2 out to the next machine.

Load DoorsHere

Load DoorsHere

HereLoad Doors

To Next Machine To Next Machine

XFER

With Transfer ON the doors flow from Stack #1 to Stack #2. Typically this mode is used in conjunc-tion with the Door manipulation (see page 3-8) to reorienting doors within a stack.

Remove Doors Here

Load Doors

Stack #1

Stack #2

XFER


Stack Control:

Holding this button will raise Stack One’s Door

Lift.

Holding this button will lower Stack One’s Door Lift.

Holding this button will raise Stack Two’s Door

Lift.

Holding this button will lower Stack Two’s Door Lift.

NavigationMAINTE-NANCE

page 3-20

GO TO LOCAL

page 3-11

• Local Data: Opens the Main Menu Local Data screen. See page 3-11 for more details.• Maintenance: Opens the maintenance screen. See page 3-20 for details.

STACK#1PICK-UP

LOAD POS

Infeed End

Outfeed End

Stack #1

STACK#2PICK-UP

LOAD POS

Infeed End

Outfeed End

Stack #2


Touch Screen

Main Menu LOCAL

MAINTE-NANCE

page 3-20

GO TO REMOTEpage 3-11

FLIP ROT:ONRDY READY

OK TO FEED-OUT

123.45

NO ACCESSI-14

LOAD POS

LONG[>96”]

PICK-UP

LOAD POS

PICK-UP

LONGSTACK

#1STACK

#2

READYENTRY

TRANSFER#1 -> #2

FLIPOFF

ROT:OFF

DOOR WIDTH

PRESET EDIT

Door WidthEntry

Running Data

Lift: Move andMode Control

Navigation

Feed ModeControl

17.2524.0036.0048.00

DoorWidth

DATA

SLOW JOGFORWARD

JOGREVERSE

AUTOFEED

FEEDTHRU

MANUALFEED

The Main Menu LOCAL screen allows direct control of the machine from the operator’s station.

Running Data:

FLIP ROT:ONRDY READY123.45 LONG

DoorWidth

DoorLength

Door ManipulationParameters

Door StackStatus

This portion of the display show door data for the door currently being processed.


Door Width Entry:

LONG[>96”]

READYENTRY

FLIPOFF

ROT:OFF

DOOR WIDTH

PRESET EDIT

17.2524.0036.0048.00

DoorWidth

DATA

FLIPON

ROT:OFF

Door Width Select:Steps through the four Door Width Presets

Doo

r Len

gth

DoorWidth

Doo

r

Door Length Select Toggles between:

for doors longer than 96”.

For doors 96” or shorter.

LONG[>96”]

SHORT<=96”

Door Manipulation Parameters:

Sets the door’s orientation parameters. For more information see “Door Manip-ulation Parameters:” on page 3-12

Door Width Preset Edit:

Allows editing of door width preset val-ues. For more information see “Door Width Preset Edit:” on page 3-13

• Door Manipulation Parameters: The Door Manipulation indicators, Flip and Rotate, indicate how the machine will orient the door before the door leaves the machine. The four possible states are shown below.

Flip OFF, Rotate OFF:

No manipulation.

FLIP

LatchSide

HingeSide

Top

Bottom

ROT

Flip ON, Rotate OFF:

The door is flipped on it’s long axis.

FLIP

LatchSide

HingeSide

Top

Bottom

LatchSide

HingeSide

Top

BottomBefore Flip After Flip

ROT

Flip OFF, Rotate ON:

The door is rotated on it’s short axis.

LatchSide

HingeSide

Top

Bottom

LatchSide

HingeSide

Top

BottomBefore Rotate After Rotate

ROTFLIP

Flip ON, Rotate ON:

The door is flipped on it’s long axis, rotated on it’s short axis.

LatchSide

HingeSide

Top

BottomBefore Flip & Rotate After Flip & Rotate

LatchSide

HingeSide

Top

Bottom

FLIP ROT


Touch Screen

• Door Width Preset Edit: Door width Preset

Edit40.25

SAVE & EXIT

PREVIOUS MENU

7 8 9

4 5 6

1 2 3

0 DEC(.)

FRC(/)

CLR

ENTERDW1-mode

DOOR-WIDTH17.2524.0036.0048.00

DOOR-WIDTH-1DW-1DW-2DW-3DW-4

17.2524.0036.0048.00

PRESET NEW

MAX. DOOR-WIDTH = XX.XX

The Door Width Preset Edit button Calls the Door Width Edit screen shown below. Use this screen to modify the door four width presets.

How to change a door width preset:

1.Use the Door Width Preset selector button to scroll to the desired preset.

DOOR-WIDTH-1DW-1DW-2DW-3DW-4

2.Use the Key Pad to enter the new door width preset value. The keyed in value will appear in the Key Pad Display. Fractional values can be entered as decimal number or fractions (see page 3-14). The value entered must be less than the Max. DOOR-WIDTH value displayed to the right of the key pad.Note: To clear a value press the CLR (clear) button.

40.25

7 8 9

4 5 6

1 2 3

0 DEC(.)

FRC(/)

DOOR-WIDTH

CLRKey Pad

Key PadDisplay

ClearButton

3.After the new value has been keyed in press the Enter key. This will load the keyed value into the “New” section of the display.

ENTERDW1-mode 40.25

7 8 9

DOOR-WIDTH40.2524.0036.0048.00

NEW

4.Save or discard changes: 17.2524.0036.0048.00

PRESET

PREVIOUS MENU

Exit with

40.2524.0036.0048.00

DW-1DW-2DW-3DW-4

NEW

SAVE & EXITExit and

no Change Save New values

• Save and Exit will save the values displayed in the “New” section of the display as door width preset values.

• Previous Menu will exit leaving the “Preset” values as door width preset values.


Entering Fractional Values:

For decimal mode enter the number using the Decimal Point key.

For fractional input enter the whole number then press the Fraction Key.

The Fractional Key displays the screen shown to the right. When a Fractional key is pressed the value is displayed is shown in thirty seconds of an inch. For example if 1/4 is pressed, 08/32 will be displayed.When the correct value has been entered press previous menu to return to the previous screen.

Lift: Move and Mode

LOAD POS

PICK-UP

LOAD POS

PICK-UP

STACK#1

STACK#2

TRANSFER#1 -> #2

Control

Stack Control:

Holding this button will raise Stack One’s Door

Lift.


DEC(.)

FRC(/)

[11/32] 42.34375

1/32 1/16 3/32 1/8 5/32 3/16 7/32 1/4

9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2

17/32 9/16 19/32 5/8 21/32 11/16 23/32 3/4

25/32 13/16 27/32 7/8 29/32 15/16 31/32

42

PREVIOUS MENU

Whole Number Fractional Number

STACK#1PICK-UP

LOAD POS

Infeed End

Outfeed End

Stack #1


Touch Screen


Lift.


• Stack Select buttons:

Use this button to select doors from Stack #1.

Use this button to select doors from Stack #2.

• Transfer #1 -> #2: TRANSFER#1 -> #2

TRANSFER#1 -> #2

The Transfer button determines the product flow path. With Transfer OFF the doors flow out to the next machine.

Load DoorsHere

Load DoorsHere

HereLoad Doors

To Next Machine To Next Machine

TRANSFER#1 -> #2

STACK#2PICK-UP

LOAD POS

Infeed End

Outfeed End

Stack #2

STACK#1

STACK#2

Infeed End

Outfeed End

Stack #2Stack #1


With Transfer ON the doors flow from Stack #1 to Stack #2. Typically this mode is used in con-junction with the Door manipulation (see page 3-12) to reorient doors within a stack.

Remove Doors Here

Load Doors

Stack #1

Stack #2

TRANSFER#1 -> #2

Feed Mode



• Feed through: In this mode the door will move through the machine without being processed.

Navigation

• Remote Data: Opens the Remote Data screen. See page 3-7 for more information.• Maintenance: Opens the Maintenance screen. See page 3-20 for more information

Ready Enter Data

READYENTRYDATA

Press this button to start the process after the door data, and the door have been entered into the machine.


Touch Screen

How to Run a Door in Manual Local Mode:

1.Load the door or doors into the machine.2.Select the Stack

STACK#1

STACK#2

3.Raise the stack to clamping height.

PICK-UP

4.Enter the door data.

LONG[>96”]

FLIPON

ROT:OFF

DoorWidth

5.Select the ModeTRANSFER

#1 -> #2

6.READYENTRYDATA

Press Ready Enter-Data to start the process.


Manual Mode

123.45

PREVIOUS MENU

MANUALFEED

FORKLIFT

FEED MODE

JOGREV

CARRIAGE

MANUAL FEED

123.45

AUTOFEED UNCLAMP

SLOW JOGFWD

UP

DOWN

#2#1

LIFT #1 LIFT #2

PositionIndicators

DOWN

UP

DOWN

UP

DOWN

RESETSEQUENCE

This screen give manual control to the operator.

Reset Sequence:

Use this button to return the ON-2010 back to a known state after any manual move.

Forklift Control:

Holding this button will move the Forklift up.

Holding this button will move the Forklift down.

Carriage Control:

Holding this button will move the Carriage and Vacuum Clamp toward stack 1.

Holding this button will move the Carriage and Vacuum Clamp toward stack 2.

RESETSEQUENCE

UP

DOWN

#1

#2

Infeed End

Outfeed End

Stack #1 Stack #2


Touch Screen

Stack Control:

Holding this button will raise Stack One’s Door Lift.




• CLAMP UNCLAMP : This button has two states, Clamp (Red) and Un-Clamp (Green).

When the button is Green the vacuum is applied to the Vacuum Clamp. When the button is Red, the Vacuum is removed from the Vacuum clamp.

Feed Mode:



STACK#1LIFT

UP

DOWN

Infeed End

Outfeed End

Stack #1

STACK#2LIFT

UP

DOWN

Infeed End

Outfeed End

Stack #2


Maintenance -1

PREVIOUS MENU

page 3-11

123.45

FORKLIFTCHANGE

124

130

123.45

MANUAL FEED

JOGREVERSE SLOW JOG

FORWARD

NEXT PAGE

page 3-21

MANUAL MODE

page 3-18

MODBUSMODE

PLC Port-1MODE

172-SCN1_1v1

POSITION

CARRIAGECHANGEPOSITION

CMD ACK

FORK

CARR

Data:

• Fork: Shows the current position of the fork.• Carriage: Shows the current servo position of the carriage.

Change Position:

• Forklift Change Position: Displays the Forklift Change Position menu. Parameters on this screen are factory set and should need no modification.

• Carriage Change Position: Displays the Carriage Change Position menu. Parameters on this screen are factory set and should need no modification.

Feed Mode



• Feed through: In this mode the door will move through the machine without being processed.• Call Door:

Manual Feed:

• Jog Rev (Jog Reverse): Turns on the feed system in reverse mode if the Feed Mode is set to manual.• Slow: This button when pressed with either Jog Rev or Jog Fwd puts the feed system in slow mode.• Jog Fwd (Jog Forward): Turns on the feed system in reverse mode if the Feed Mode is set to man-

ual.

Navigation:

• Manual More: Opens the Manual Mode screen. See page 3-18 for more information.• Next Page: Opens the second maintenance page. See page 3-21 for more information.


Touch Screen

• Previous Menu: Opens the previous page.

Maintenance -2

PREVIOUS MENU

page 3-2012

12

CONTRAST LEVEL (0 - 31)

COLOR BRIGHT-NESS (0 - 31)

PLC INPUT-OUTPUT

PLC TIMER STATUS

SCRIPT&DRIVESTATUS

PLC M_BIT STATUS

MACHINE DATApage 3-22

TECH SUPPORT page 3-22

Touch Screen view adjustments:

• Color Brightness: Adjusts the touch screen’s brightness. • Contrast Level: Adjusts the touch screen’s contrast level.

Navigation:

• PLC Input-Output: Opens a trouble shooting screen.• PLC Times Status: Opens a trouble shooting screen. • Script & Drive Status: Opens a trouble shooting screen.• PLC M_BIT Status: Opens a trouble shooting screen.• Machine Data: Opens the Machine Data Screen. See page 3-22 from more information.• Tech Support: Opens the Tech Support screen. See page 3-22 for more information.• Previous Menu: Opens the previous screen.


Machine Data

MACHINE DATAMACHINE TOTAL

DAILY TOTAL

1,004,576

842

RESET PREVIOUS MENU

page 3-21DAILY

• Machine Total: Displays the count of completed milling cycles.• Daily Totals: Displays the total number of milling cycles completed since Reset Daily was pushed.• Reset: Resets Daily Totals to 0.• Previous Menu: Returns to the previous menu.

Technical Support

Previous Screen

page 3-21

TECHNICAL SUPPORT4:00 A.M to 4:30 P.M. (PACIFIC TIME)

MONDAY through FRIDAYPH: 800-553-5825

This screen displays KVAL’s support contact information. For more information visit www.kvalinc.com.


Homing the ON-2010

Homing the ON-2010The Rail 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 Rail measures its motion when making cuts.You should home the Rail:

• After powering up the system• After hitting the STOP then START buttons• When recovering from an Emergency Stop

To Home the ON-2010

1.On the touch screen Press OK to HOME.

O.K. TO HOME

Note: If there is a door in the Rail machine see step 6. under “How to Manually remove uncompleted doors from the line:” on page 1-16.


CHAPTER 4 Calibrating the ON-2010

Coming Soon

Alliance Series 4-1

Calibrating the ON-2010

4-2 Alliance Series

CHAPTER 5 FACE

This chapter provides operating instructions for the KVAL FACE.

Alliance Series 5-1

FACE

5-2 Alliance Series

FACE - Operator’s Tour:

FACE - Operator’s Tour:

Infeed

Outfeed

HeadRight Hand Stops

Left Hand Stops

Operator’sStation

Control

Start Machine

START

STOP

Disable AutoFeed

Reset Drives

Drills 5&6Speed Adjust

ControlTransformer

Start SequenceRouter

#1

Router#2

Router#3

Router#4

Panel

• Control Transformer: Applies electrical power to control circuits and computer.• Start Machine: Applies electrical power to drive circuits.• Start Sequence: Starts processing the door.• Drills 5&6 Speed Adjust: Speed adjust for the top and bottom function drills.• Disable Auto Feed: Turns Auto Feed off. • Reset Drives: Resets faulted motor drives.• Touch Screen: See “Touch Screen” on page 5-5 for more information.• Router #1: If lit indicates Router High Frequency Motor Drive One faulted. Press to reset.• Router #2: If lit indicates Router High Frequency Motor Drive Two faulted. Press to reset.• Router #3: If lit indicates Router High Frequency Motor Drive Three faulted. Press to reset.• Router #4: If lit indicates Router High Frequency Motor Drive Four faulted. Press to reset.

Alliance Series 5-3

Cutting Head

There are six tools available, three for the top face of the door and three for the bottom face of the door. The FACE machine will automatically chose a tool based on door face, top or bottom, and cut size. Most machines are equipped with four routers and two drills. Top Tool Numbers

Bottom Tool Numbers 4 2 6

3 1 5

Routers

Drills

Routers

5-4 Alliance Series

Touch Screen

Main Screen

CLAMP/

38-00-SCN5_1v1

S P E E DD E P T H O F C U T

F E E D M O D E

MANUAL OPERATION

AUTO

1 32 4A CB D

UNCLAMP

DRIVE FAULT

TROUBLE SHOOTING

MANUAL RUN

page 5-6

TouchScreenProgram Version

Drive Fault

OFFFEEDTHRU

Manual ModeIndicator HOMINGHOMING Homing

Indicator

Indication

• Depth of Cut: Adjusts the depth of cut per pass where A is a lesser depth and D is greater depth. Use a lesser depth of cut for harder material and a greater depth of cut for softer material.

• Speed: Sets the cutting speed where 1 is minimum and 4 is maximum. Use a slower speed for harder material and a faster speed for softer material.

• Feed Mode: Puts feed system into one of three modes:Off (Red): Feed system is in full manual control.Auto (Green): Feed system is in fully automatic mode.Feedthru (Aqua): Feed system is in fully automatic mode, but the machine will not process the door.

• Touch Screen Program Version: Indicates the touch screen’s program version. Have this number available when calling KVAL for troubleshooting assistance.

• Clamp/Unclamp: Toggles the feed system’s door clamp between clamped and unclamped.• Manual Mode Indicator: Indicates the machine is in manual operating mode.• Homing Indicator: Indicates the machine is performing the homing process.• Drive Fault Indicator: Indicates a drive fault.• Trouble Shooting: Calls the Trouble Shooting screen.• Manual Run: Calls the Manual Run screen. See “Manual Run Screen” on page 5-6 for more infor-

mation.

Face 5-5

Manual Run Screen

JOGReverse SLOW JOG

Forward

JOGOpen

DRIVE FAULT

M A N U A L F E E D

MANUAL WIDTH ADJUST

F E E D M O D E

TROUBLE SHOOTING

AUTO RUN

page 5-5

JOGClose

MANUAL

CLAMP/AUTO UNCLAMPOFFFEEDTHRU

Manual ModeIndicator

Drive FaultIndication

• Feed Mode: Puts feed system into one of three modes:Off (Red): Feed system is in full manual control.Auto (Green): Feed system is in fully automatic mode.Feedthru (Aqua): Feed system is in fully automatic mode, but the machine will not process the door.

• Clamp/Unclamp: Toggles the feed system’s door clamp between clamped and unclamped.• Manual Width Adjust:

JOG Open: Feed system will open when this button is pressed. This is a momentary button. The action will only occur when the button is pressed.JOG Closed: Feed system will close when this button is pressed. This is a momentary button. The action will only occur when the button is pressed.

• Manual Mode Indicator: Indicates the machine is in manual operating mode.• Manual Feed:

JOG Reverse: Moves the feed system in the reverse direction. This is a momentary button. The action will only occur when the button is pressed.SLOW: Puts the feed system in slow mode. Works in conjunction with JOG Reverse and JOG For-ward. This is a momentary button. The action will only occur when the button is pressed.JOG Forward: Moves the feed system in the forward direction. This is a momentary button. The action will only occur when the button is pressed.

• Drive Fault Indicator: Indicates a drive fault.• Trouble Shooting: Calls the Trouble Shooting screen.• Manual Run: Calls the Manual Run screen. See “Manual Run Screen” on page 5-6 for more infor-

mation.

5-6 Face

Homing the Face

Homing the FaceThe Face 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 Face measures its motion when making cuts.You should home the Face:


To Home the Face

1. Remove any doors from the feed system.2. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button

below it to read Home.3. Click twice on the Home button. The Face should start the homing operation.

NOTE:While the homing operation is in progress, the Home button changes its label to Homing.

Alliance Series 5-7

5-8 Alliance Series

Router Collets

Router ColletsTool Insertion

Router Protrusion 1 7/8”

1.Insert tool into collet with the correct protrusion length from the collet face to the tip of the tool as shown above.

Note: The protrusion distances shown above are for standard machines. The protrusion distance can vary depending on the bit length and required cut depth. Regardless of the protrusion distance, insure there is a minimum of 1/8” clearance from the end of the bit to the bottom of the tool holder.2.Tighten the tool holder nut using the appropriate

wrenches.Note: Most machines come with a gauge to set this distance.

Collet Maintenance

Periodically remove the collet assembly and use a compressed air gun to blow out debris from both the nut and collet.Check the collet for bluing (overheating) or physical damage. If there is overheating or physical damage the collet must be replaced.

Note: When inserting the collet into nut insure collet “snaps” into the nut.

Collet

1/8” minimum

NutBit

“Snap”

Alliance Series 5-9

CHAPTER 6 Calibrating the FACE

Face 6-1

Calibrating the FACE

How to modify a Parameter:1.In the KVAL 2006 interface, click once on the Maint button.2.Click the Cal button. 3.You will see a message pop up in front of the graphic display area. This is a warning message, inform-

ing you that if you proceed, it will abort any cutout progra.

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

5.Click the Calibration button. This takes you to the calibration pages where the calibration takes place. The first page displayed is Calibration Page 1:

6.Use the Page up and Page Down buttons to navigate to the desired parameter.7.See “Parameters” on page 6-4. to find the parameter to modify. Use the following process to modify

the parameter value.a.Integrate the Modifier (if needed):

6-2 Face

How to modify a Parameter:

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.

(Modifier field has a non-zero value)Example:(Click on the left-most field)

(Offset is updated, Modifier field is empty)

b.Type the new value in the right-hand field, press the Enter key, and then click the left-most field to register the new offset.

Note: Some parameters are protected against modification. Parameter protection is indicated by an asterisk (*) at the end of the field name. Also if an attempt is made to modify a protected parameter Combined Variables Protected message is displayed. To temporarily defeat the protection press the Protect Cal button.When you are finished making the calibration adjustments, click the Exit button. This exits the Calibra-tion page and the KVAL 2006 program.

Face 6-3


ParametersTool size and Cutting Depth

Top Main Router Top MainRouter

Enter the diameter of the Top Main Router bit.

Top Router Depth

Increasing this parameter will increase the depth of the Top Main Router plunge.

Bottom Main Router

Router MainBottom

Enter the diameter of the Bottom Main Router Bit.

Bottom Main Router Depth

Increasing this parameter will increase the depth of the Bot-tom Main Router plunge.

D1 Top D1 TopTool

Enter the diameter of the D1 Top router bit.

D1 Top Depth

Increasing this parameter will increase the depth of the D1 Top router plunge.

+

-Door Face

Deeper

Shallower

+

-Door Face

Deeper

Shallower

+

-Door Face

Deeper

Shallower

6-4 Face

Parameters

D1 Bottom

D1 BottomTool

Enter the diameter of the D1 Bottom router bit.

D1 Bottom Depth

Increasing this parameter will increase the depth of the D1 Bottom router plunge.

D2 Top D2 TopTool

Enter the diameter of the D2 Top drill bit.

D2 Top Depth

Increasing this parameter will increase the depth of the D2 Top drill plunge.

D2 Bottom

D2 BottomTool

Enter the diameter of the D2 Bottom drill bit.

D2 Bottom Depth

Increasing this parameter will increase the depth of the D2 Bottom drill plunge.

+

-Door Face

Deeper

Shallower

+

-Door Face

Deeper

Shallower

+

-Door Face

Deeper

Shallower

Face 6-5


Automated Tool Selection

D1 PegNot used.

D1 NegNot used.

D2 Neg

D1 Pos

ToolDiameter

D1 Neg

and ActualHole Size

MaximumDiameter

MinimumDiameter

This parameter sets the minimum diameter cut to use the D2 Tools. The value entered will be subtracted from the tool diameter set in the D2 Top and D2 Bottom parameters. The bit in the D2 Tool will determine the actual cut diameter.

D2 Pos

This parameter sets the minimum diameter cut to use the D2 Tools. The value entered will be added from the tool diameter set in the D2 Top and D2 Bottom parameters. The bit in the D2 Tool will determine the actual cut diameter.

D2 Tools

6-6 Face

Parameters

Cut Location

Top Main Router X

Factory set to 0. No adjustment necessary.

Top Router Y

Factory set to 0. No adjustment necessary.

Face 6-7


D1 X

D1 Tools

+-Cut Position

Infeed

X Axis

Sets the position of the cut referenced to the infeed end of the machine along the X axis for cuts using the D1 Tools. Increasing this parameter value will move the cut away from the infeed end of the machine. Reducing this parameter will move the cut toward the infeed end of the machine.Note: This parameter is referenced to the Top Main Router X parameter. Insure the Top Main Router X parameter is set correctly before adjusting the D1 X parameter.Since this parameter is referenced to the infeed end of the machine and not the top of the door, it will affect each hand differently. See below:

D1 Y

+-

Lock Side

Sets the position of the cut referenced to the lock side of the door for cuts using the D1 Tools. Increasing this parameter value will move the cut away from the lock side of the door. Reducing this parameter will move the cut toward the lock side of the door.Note: This parameter is referenced to the Top Main Router Y parameter. Insure the Top Main Router Y parameter is set correctly before adjusting the D1 Y parameter.

Left Hand Door

Top of Door

Right Hand Door

Top of Door

+

-

-

+

6-8 Face

Parameters

D2 X

+-Cut Position

Infeed

D2 ToolsX Axis

Sets the position of the cut referenced to the infeed end of the machine along the X axis for cuts using the D2 Tools. Increasing this parameter value will move the cut away from the infeed end of the machine. Reducing this parameter will move the cut toward the infeed end of the machine.Note: This parameter is referenced to the Top Main Router X parameter. Insure the Top Main Router X parameter is set correctly before adjusting the D2 X parameter.Since this parameter is referenced to the infeed end of the machine and not the top of the door, it will affect each hand differently. See below:

D2 Y

+-

Lock Side

Sets the position of the cut referenced to the lock side of the door for cuts using the D1 Tools. Increasing this parameter value will move the cut away from the lock side of the door. Reducing this parameter will move the cut toward the lock side of the door.Note: This parameter is referenced to the Top Main Router Y parameter. Insure the Top Main Router Y parameter is set cor-rectly before adjusting the D1 Y parameter.

Left Hand Door

Top of Door

Right Hand Door

Top of Door

+

-

-

+

Face 6-9


Left Hand X

+-Top ofCut

Position the Door

L e f t H a n d S t o p sAdjusts the position of a cut referenced ALL Left Hand Stops.

• Increasing this value will move the cut closer to the Top of the Door.

• Decreasing this parameter will move the cut farther from the Top of the Door.

Right Hand X

+-Top of Cut

Positionthe Door

R i g h t H a n d S t o p sAdjusts the position of a cut referenced ALL Right Hand Stops.

• Increasing this value will move the cut farther from the Top of the Door.

• Decreasing this parameter will move the cut closer to the Top of the Door.

6-10 Face

Parameters

SSX1:

Position of mid machine photo eyes. Factory set, no adjustment necessary.

SSX2:

Position of mid machine photo eyes. Factory set, no adjustment necessary.

SSX3

Not used.

SSX4

Not used.

SSX5

Not used.

Face 6-11


Left Stop Calibrations

Left Stop 1

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

1

+-Top ofCut

Position the Door

Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 1.



• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 1 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 1 calibration if it is the only cut out of calibration.

Left Stop 2

1 2 3 4 5 6 7 8 9 10 11

Left Hand Stops

1234567891011

Right Hand Stops

2

+-Top ofCut

Position the Door




• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 2 is replaced. To determine if this parameter needs cal-ibration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 2 calibration if it is the only cut out of calibration.

6-12 Face

Parameters

Left Stop 3

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

3

+-Top ofCut

Position the Door





Left Stop 4

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

4

+-Top ofCut

Position the Door




• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 4 is replaced. To determine if this parameter needs cal-ibration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 4 calibration if it is the only cut out of calibration.

Face 6-13


Left Stop 5

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

5

+-Top ofCut

Position the Door





Left Stop 6

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

6

+-Top ofCut

Position the Door




• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 6 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 6 calibration if it is the only cut out of calibration.

6-14 Face

Parameters

Left Stop 7

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

7

+-Top ofCut

Position the Door





Left Stop 8

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

8

+-Top ofCut

Position the Door




• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 8 is replaced. To determine if this parameter needs cal-ibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 8 calibration if it is the only cut out of calibration.

Face 6-15


Left Stop 9

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

9

+-Top ofCut

Position the Door




• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 9 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 9 calibration if it is the only cut out of calibration.

Left Stop 10

1 2 3 4 5 6 7 8 9 10 11

Left Hand Stops

1234567891011

Right Hand Stops

10

+-Top ofCut

Position the Door

Left Hand StopsAdjusts the position of a cut refer-enced to Left Hand Stop 10.



• NOTE: This parameter is factory set and typically will not need adjustment. It may need adjust-ment if the Left Hand Stop 10 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 10 calibration if it is the only cut out of calibration.

6-16 Face

Parameters

Left Stop 11

1 2 3 4 5 6 7 8 9 10 11

Left Hand Stops

1234567891011

Right Hand Stops

11

+-Top ofCut

Position the Door

Left Hand StopsAdjusts the position of a cut refer-enced to Left Hand Stop 11.



• NOTE: This parameter is fac-tory set and typically will not need adjustment. It may need adjustment if the Left Hand Stop 11 is replaced. To deter-mine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 11 calibration if it is the only cut out of calibration.

Face 6-17


Right Stop Calibrations

Right Stop 1

1 2 3 4 5 6 7 8 9 10 11

Left Hand Stops

1234567891011

Right Hand Stops

1

+-Top of Cut Position

the Door

Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 1.



• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 1 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 1 calibration if it is the only cut out of calibration.

Right Stop 2

1 2 3 4 5 6 7 8 9 10 11

Left Hand Stops

1234567891011

Right Hand Stops

2


the Door





6-18 Face

Parameters

Right Stop 3

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

3


the Door




• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 3 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 3 calibration if it is the only cut out of cali-bration.

Right Stop 4

1 2 3 4 5 6 7 8 9 10 11

Left Hand Stops

1234567891011

Right Hand Stops

4


the Door





Face 6-19


Right Stop 5

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

5


the Door





Right Stop 6

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

6


the Door





6-20 Face

Parameters

Right Stop 7

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

7


the Door





Right Stop 8

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

8


the Door





Face 6-21


Right Stop 9

1 2 3 4 5 6 7 8 9 1011

Left Hand Stops

1234567891011

Right Hand Stops

9


the Door





Right Stop 10

1 2 3 4 5 6 7 8 9 10 11

Left Hand Stops

1234567891011

Right Hand Stops

10


the Door





6-22 Face

Parameters

Right Stop 11

1 2 3 4 5 6 7 8 9 10 11

Left Hand Stops

123456789101111


the Door





•

Face 6-23


6-24 Face

CHAPTER 7 Architect DI-DM

This chapter provides operating instructions for the KVAL Architect DI-DM.

Alliance Series 7-1

Architect DI-DM

7-2 Alliance Series

Architect DI-DM - Operator’s Tour

Architect DI-DM - Operator’s Tour

Feed Direction

Infeed End

Outfeed End

BackSection

FrontSection

Operator’sStation

ElectricalCabinets

HeadOne

HeadTwo

HeadThree

HeadFour

Control Panel:

Machine

START

STOP

Deep MortiseBlow OFF

ControlTransformer

Start Sequence

OFF ONTouch Screen

• Control Transformer: Applies electrical power to control circuits and computer.• Machine: Applies electrical power to drive circuits.• Start Sequence: Starts processing the door.• Deep Mortise Blow OFF: Turns the Deep Mortise blow off ON or OFF. • Touch Screen: See “Touch Screen” on page 7-4 for more information.

Alliance Series 7-3

Touch ScreenMain Screen

MANUAL RUN

page 7-5

MACHINE DATA

page 7-6

TROUBLE SHOOTING

Feed Select

• Off: Feed system stops.• Auto Feed: Doors will enter the machine, be processed and sent out with no operator intervention.• Feed Thru: Doors will pass through the machine without being processed.

Back Section Speed

• This sets the cutting speed of the backsection. Pressing this button will increment the speed range. Range values are from 1 to 4. If the indicator is on range 4 and the range button is pressed the speed range will drop back to 1.

Hinge Speed

• This sets the cutting speed of the front section. Pressing this button will increment the speed range. Range values are from 1 to 4. If the indicator is on range 4 and the range button is pressed the speed range will drop back to 1.

Navigation

• Trouble Shooting: Opens the Trouble Shooting screen.• Machine Data: Opens the Machine Data screen. See “Machine Data Screen” on page 7-6.• Manual Run: Opens the Manual Run screen. See “Manual Run Screen” on page 7-5.

7-4 Alliance Series

Touch Screen

Manual Run Screen

TROUBLE SHOOTING

MAIN MENU

page 7-4

• Start Sequence: Starts the milling process.• Stop Up/Down: Toggles the door stops up or down.• Clamp Unclamp: Toggles the clamp clamped or unclamped.

Manual Feed

• Jog Reverse: Moves the feed in the reverse direction.• Fast: Pressing this button in conjunction with Jog Reverse or Jog Forward puts the feed in fast

mode. • Jog Forward: Moves the feed in the forward direction.

Navigation

• Trouble Shooting: Opens the trouble shooting menu.• Main Menu: Opens the Main menu. See “Main Screen” on page 7-4.

Alliance Series 7-5

Machine Data Screen

• Total Count: Displays the count of completed milling cycles.• Total Running Hours: Displays the total running time in hours of the machine.• Daily Count: Displays the total number of milling cycles completed since Daily Reset was pushed.• Daily Running Hours Mins: Displays the total running time of the machine since Daily Reset was

pushed.• Reset Daily: Resets both Daily Count and Daily Running Hours Mins to 0.• Previous Menu: Returns to the previous menu.

7-6 Alliance Series

Homing the Architect DI DM

Homing the Architect DI DMThe Architect DI DM must go through a homing routing before any other operation is performed. Per-forming the homing routine establishes a home position - a zero-reference position from which the Architect DI DM measures its motion when making cuts.You should home the Architect DI DM:


To Home the Architect DI DM

1.Maint

Home

OKHome?

Homing

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 the Home button. This will change the button label to OK to Home?3.CLick the OK to Home? button.4.NOTE:While the homing operation is in progress, the Home button changes its label to Homing.

Alliance Series 7-7

7-8 Alliance Series

Router Collets

Router ColletsTool Insertion

Router Protrusion Front Hinge Router 2”Back Section Routers 5 3/4”

1.Insert tool into collet with the correct protrusion length from the collet face to the tip of the tool as shown above.

Note: The protrusion distances shown above are for standard machines. The protrusion distance can vary depending on the bit length and required cut depth. Regardless of the protrusion distance, insure there is a minimum of 1/8” clearance from the end of the bit to the bottom of the tool holder.2.Tighten the tool holder nut using the appropriate

wrenches.Note: Most machines come with a gauge to set this distance.

Collet Maintenance

Periodically remove the collet assembly and use a compressed air gun to blow out debris from both the nut and collet.Check the collet for bluing (overheating) or physical damage. If there is overheating or physical damage the collet must be replaced.


Collet

1/8” minimum

NutBit

“Snap”

Alliance Series 7-9

CHAPTER 8 Calibrating the Architect DI-DM

Architect DI DM 8-1

Calibrating the Architect DI-DM







8-2 Architect DI DM







Architect DI DM 8-3


ParametersFront Section

Pocket Definitions

Feed Direction

Predrill cuts

Chisel cuts

Hinge Pocket

Door

Hinge LocationsHinge 1 Hinge 2 Hinge 3 Hinge 4

Infeed Outfeed

Full Front section Calibration Procedure

1.Set Hinge Backset.2.Set Predrill Vert.3.Set Hn Vert. (n = hinge number)4.Set Hn Horiz. (n = hinge number)

8-4 Architect DI DM

Parameters

Pocket Parameters - Predrills

Feed Direction

Notes:• Increasing the parameter value will move element in the

direction of parameter arrow.

Predrill n Vert

n = Hinge number

Pocket Parameters - General

Hn 3deg Vert (Set Hn Vert Offset first) Hn Vert Offset

Hn Left Side (Note: Predrill holes remain stationary)

Hn X Offset Chisel LL Hn X Offset Chisel LR

Hn Y Offset to Chisel LL Hn Y Offset to Chisel LR

Hn LH X Offset (For Left Hand mode)Hn RH X Offset (For Right hand mode)

Feed Direction

n = Hinge number


direction of parameter arrow.• All parameters are for both left and right hand unless noted.

Architect DI DM 8-5


Router Diameter

Hn Router Diam

Notes: • The router diameter is normally set to the diameter of router bit. • Increasing this value decreases the size of the hinge pockets.

Hn = Hinge Number

General Front Section:

HINGE Z Each Pass

Increasing this parameter will increase the depth of cut for each pass of the hinge router plunge.

Hinge Outfeed Stop

Increasing this parameter will move all hinge locations away from the infeed stop (For left hand or right hand reverse modes).

Hinge Infeed Stop:

Increasing this parameter will move all hinge locations away from the infeed stop (For right hand mode only).

8-6 Architect DI DM

Back Section

Back SectionRouter

Router Horizontal, Vertical



3deg Vert (Set Vert Offset first)

Feed Direction

*Set front section hinge locations before

Vert Offset

Lock Location RH (For Right Hand mode)*Lock Location LH (For Left hand mode)*

setting these parameters.

Router Diameter

Router Diam

Increasing the Router Diam value decreases the size of the Face plate pockets.

Architect DI DM 8-7


Router Depth

Increasing this parameter will increase the depth of the router plunge.

3 Deg Depth

Increasing this parameter will increase the depth of the router plunge in 3 degree mode.NOTE: Calibrate Router depth first.

Z Each Pass:

Increasing this parameter will increase the depth of cut for each pass of the router plunge.

Chisels

Note: Increasing the parameter value will move the element in the direction off the parameter arrow.

X Offset to Chisel UL

Y Offset to Chisel UL

Y Offset to Chisel LL

X Offset to Chisel LL

Y Offset to Chisel LR

X Offset to Chisel LR

X Offset to Chisel UR

Y Offset to chisel UR

Z Offset to Chisel aa

Increasing this parameter will increase the depth of the chisel (aa = chisel location UL, LL, UR, LR).

8-8 Architect DI DM

Back Section

Deep Mortis



Feed Direction

DM Vertical (Set Router Vert

Deep Mortis X

Offset and 3deg. Vert before adjusting this parameter)

DM Diameter

Feed DirectionNotes:

• Increasing the DM Diameter value decreases the size of the deep mortise pocket.

• For a faster cut increase the router bit size. If the bit diameter is the same size as the cut, the router will make the cut in one pass.

• A smaller router bit will result in a squarer hole

DM Diameter

Z Ech DM Pass:

Increasing this parameter will increase the depth of cut for each pass of the deep mortis plunge.

DM Depth:

Increasing this parameter will increase the depth of the deep mortis plunge.

Architect DI DM 8-9


Counter Rotating Router


direction of parameter arrow.• If x or y get out of adjustment, making it cut too deep on Z

is a good way to “find” the cut and get it calibrated relative to the main router bit.

Feed Direction

Cnt Rout Vert (Set Router Vert

Cnt Rout Horiz X


Cnt Rout Diam (Counter Router Diameter)

Notes: Increasing the Cnt Rout Diam value decreases the size of the Counter Rotating

Cnt Rout Depth:

Increasing this parameter will increase the depth of the Counter Rotating Router plunge.

8-10 Architect DI DM

Back Section

Side Drills



Side Drill Y (Set Router VertOffset and 3deg. Vert before

Feed Direction

Side Drill X

adjusting this parameter)

Side Drill Z:

Increasing this parameter will increase the depth of the Side Drill plunge.

Side Drill Diam:

Enter the diameter of the side drill bit.

Note: If program calls for a side drill hole size larger than the bit, the machine will use the main router bit, typically.500” diameter to cut the hole.

Architect DI DM 8-11


General Back SectionSide Enc. 0

Side Enc. 0 determines the position of 0 for the width adjust system. There is no mechanical stop for this position so we must relay on the machine’s Side Encoder position to determine 0 width position. Calibration requires a square door with a known width.

1.Select 0º mode.2.Click on orange field until heading reads Side Encoder.

3.Load a perfectly square door as described below with a know width.4.Manually open and close the width adjust and record the value of the Side Encoder.5.Repeat step two 5 times.6.If the value found in step 4 is between +0.02 and -0.02 calibration is complete.7.Find the largest offset in step 4 and divide by 2.8.Change the sign of value found in step 6.9.Add the value calculated in step 6 to the existing Side Enc. 0.10.Go back to step 3.

Example:Five values: -0.015, -0.023, 0.005, -0.027, 0.015Find largest offset: -0.015, -0.023, 0.005, -0.027, 0.015Divide largest offset by 2: -0.027/2= -0.0135Change the sign -0.0135 becomes 0.0135Add 0.0135 to the existing Side Enc 0 value.

0 Position


General Back Section

Side Enc. 3DEG

Side Enc. 0 determines the position of 0 for the width adjust system. There is no mechanical stop for this position so we must relay on the machine’s Side Encoder position to determine 0 width position. Calibration requires a square door with a known width.

1.Select 3º mode.2.Click on orange field until heading reads Side Encoder.

3.Load a perfectly square door as described below with a know width.4.Manually open and close the width adjust and record the value of the Side Encoder.5.Repeat step two 5 times.6.If the value found in step 4 is between +0.02 and -0.02 calibration is complete.7.Find the largest offset in step 4 and divide by 2.8.Change the sign of value found in step 6.9.Add the value calculated in step 6 to the existing Side Enc. 3DEG.10.Go back to step 3.

Example:Five values: -0.015, -0.023, 0.005, -0.027, 0.015Find largest offset: -0.015, -0.023, 0.005, -0.027, 0.015Divide largest offset by 2: -0.027/2= -0.0135Change the sign -0.0135 becomes 0.0135Add 0.0135 to the existing Side Enc. 3DEG value.

0 Position



How to select a perfectly square door (or one that’s close enough)

To determine if a door is square, measure the distance between opposite corners. If the difference between the two measurements is less than 1/16”, the door is square.

A B

Square door = ∆(AB)<1/16”


Feed System

Feed SystemInfeed RH End check:

This parameter calibrates the Right Hand End Check Sensor. This sensor is located on the backsection side of the machine directly across from the infeed stop and is used to check the door for square. The calibration procedure is described below.

1.Click on orange field until heading reads Infeed Encoder.

2.Load a perfectly square door as described above. 3.Record the value of the Infeed Encoder.4.If the value found in step 4 is between +0.02 and -0.02 Infeed RH End Check calibration is complete.5.Change the sign of value found in step 3.6.Add the value found in step 5 to the existing Infeed RH End Check value.7.Go back to step 3.

Right Hand End CheckSensor Position



Outfeed LH End check:

This parameter calibrates the Left Hand End Check Sensor. This sensor is located on the backsection side of the machine directly across from the infeed stop and is used to check the door for square. The calibration procedure is described below.

1.Click on orange field until heading reads Outfeed Encoder.

2.Load a perfectly square door as described above. 3.Record the value of the Outfeed Encoder.4.If the value found in step 4 is between +0.02 and -0.02 Outfeed LH End Check calibration is com-

plete.5.Change the sign of value found in step 3.6.Add the value found in step 5 to the existing Outfeed LH End Check value.7.Go back to step 3.

Infeed Stop:

This sets the location of the Infeed stop. This parameter should always be set to 0.

Left Hand End CheckSensor Position


CHAPTER 9 EDGE

This chapter provides operating instructions for the KVAL Edge.

Alliance Series 9-1

EDGE

9-2 Alliance Series

EDGE - Operator’s Tour

Infeed

Outfeed

Operator’sStation

CuttingHead

Feed Direction

Alliance Series 9-3

Control Transformer(Maintained)

PushOff

PullOn

MACHINE

START

STOP

Mortise DepthOf Cut

1.01.5 2.0

2.5

Speed Select

70%80% 90%

100%

Auto Feed Router Depthof Cut

OffAuto

FeedThru 1.0

1.5 2.02.5

FORWARD

REVERSE

Feed DEEP MORTISE

Disable Auto Feed Disable Width Adj(Maintained)(Maintained)

PushOff

PullOn

PushOff

PullOn

BLOW OFF

OFF ON

Faster

Control Panel One

• Control Transformer: Applies electrical power to con-trol circuits and computer.

• Machine START STOP: Applies electrical power to drive circuits.

• Mortis Depth of Cut: Sets the depth of cut for each deep mortis cutting pass.

• Speed Select: Sets the cutting speed. Use higher set-tings for soft material, slower settings for hard material. If the speed ranges are not adequate for you needs please contact KVAL service.

• Auto Feed: Off Feed in manual mode. To move a door

use the Feed FWD and REV buttons.

Auto The machine will call, load and clamp a door in preparation for processing.

Feed Thru The door will be passed to the next machine without processing.

• Router Depth: Sets the depth of cut for each router pass.

• Feed: FWD Manually jogs the feed forward moving

the door toward the outfeed end of the machine.

REV Manually jogs the feed reverse moving the door toward the infeed end of the machine.

• Deep Mortise Blow Off: Turns the Deep Mortise blow off ON or OFF.• Disable Auto Feed: Stops all feed movement.• Disable Width Adjust: Stops all width adjust movement.

9-4 Alliance Series

Control Panel Two

Start Sequence

Door Clamp

Door Stop

Reset Drives

• Start Sequence: Manually starts door processing. • Door Clamp: Manually starts the door clamping process.• Door Stop: Manually extends the proper door stop. The door stop

is determined by door hand and door size.• Reset Drives: Resets the motor drives.

Alliance Series 9-5

9-6 Alliance Series

Homing the EDGE

Homing the EDGEThe EDGE 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 EDGE measures its motion when making cuts.You should home the EDGE:


To Home the EDGE

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 Edge Patriot should start the homing operation. NOTE:While the homing operation is in progress, the Home button changes its label to Homing.

Alliance Series 9-7

9-8 Alliance Series

Deep Mortise Collet

Deep Mortise ColletTool Insertion

1.Insert tool into collet with 5 3/4” from the collet face to the tip of the tool. 2.Tighten the tool holder nut using the appropriate

wrenches.5 3/4”

NOTE: Insure there is a minimum of 1/8” clearance from the end of the bit to the bottom of the tool holder.

Collet Maintenance

Periodically remove the collet assembly and use a compressed air gun to blow out debris from both the nut and collet.

Check the collet for bluing (overheating) or physical damage. If there is overheating or physical damage the collet must be replaced.


Collet

1/8” minimumNut

Bit

“Snap”

Alliance Series 9-9

CHAPTER 10 Calibrating the EDGE

Edge Patriot & Edge STS 10-1

Calibrating the EDGE







10-2 Edge Patriot & Edge STS


ParametersLock Location

Lock Location RH

Lef

t

Lef

t

Mid

dle

Rig

ht

Rig

ht

Out

boar

d

Out

boar

d

The Lock Location RH parameter sets the position of the Face Plate cut in relation to Right Stop. This stop is used when making cuts between 0” and 9’ 6” from the top of a right hand door on the hinge side. Or when making cuts between 0” and 9’ 6” from the top of a left hand door on the lock side.

- +Lock Location RH

9’ 6”

Loch Location LH

- +Lock Location LH

Lef

t

Lef

t

Mid

dle

Rig

ht

Rig

ht

Out

boar

d

Out

boar

d

The Lock Location LH parameter sets the position of the Face Plate cut in relation to Left Stop. This stop is used when making cuts between 0” and 9’ 6” from the top of a left hand door on the hinge side. Or when making cuts between 0” and 9’ 6” from the top of a right hand door on the lock side. Or for left hand top cuts and right hand bottom cuts.

9’ 6”


Parameters

Stops

Left Stop

- +Left Stop

Lef

t

Lef

t

Mid

dle

Rig

ht

Rig

ht

Out

boar

d

Out

boar

d

The Left Stop parameter sets the position of the Face Plate cut in relation to Left Stop. This stop is used when making cuts between 0” and 9’ 6” from the top of a left hand door on the hinge side. Or when making cuts between 0” and 9’ 6” from the top of a right hand door on the lock side. Or for left hand top cuts and right hand bottom cuts.

CAUTION: This calibration parameter is factory set to 0. Any adjustment to this parameter will affect all other calibration parameters.

9’ 6”

Middle Stop

Lef

t

Lef

t

Mid

dle

Rig

ht

Rig

ht

Out

boar

d

Out

boar

d

The Middle Stop parameter sets the position of the Face Plate cut in relation to Middle Stop. This stop is used for left hand bottom cuts and right hand top cuts.

- +Middle Stop



Right Stop

Lef

t

Lef

t

Mid

dle

Rig

ht

Rig

ht

Out

boar

d

Out

boar

d

The Right Stop parameter sets the position of the Face Plate cut in relation to Right Stop. This stop is used when making cuts between 0” and 9’ 6” from the top of a right hand door on the hinge side. Or when making cuts between 0” and 9’ 6” from the top of a left hand door on the lock side.

- +Right Stop

9’ 6”

Left Outboard Stop

- +Left Outboard Stop

Lef

t

Lef

t

Mid

dle

Rig

ht

Rig

ht

Out

boar

d

Out

boar

d

The Left Outboard Stop parameter sets the position of the Face Plate cut in relation to Left Outboard Stop. This stop is used when making cuts on the hinge side of a left hand door greater than 9’6” tall. Or when making cuts on the lock side of a right hand door greater than 9’ 6” tall.

9’ 6”


Parameters

Right Outboard Stop

- +Right Outboard Stop

Lef

t

Lef

t

Mid

dle

Rig

ht

Rig

ht

Out

boar

d

Out

boar

d

The Right Outboard Stop parameter sets the position of the Face Plate cut in relation to Right Outboard Stop. This stop is used when making cuts on the hinge side of a right hand door greater than 9’6” tall. Or when making cuts on the lock side of a left hand door.

Note: The Right Outboard Stop parameter is referenced to Right Stop. Any changes to the Right Stop parameter will affect the Right Outboard Stop.

9’ 6”

Deep mortise

DM Vertical

Notes: Increasing the parameter value will move element in the direction of parameter arrow, toward the upward face of the door.

DM Vertical



DM Diameter

Notes: Increasing the DM Diameter value decreases the size of the deep mortise pocket.

DM Diameter

Deep Mortise X:

Notes: Increasing the parameter value will move the deep mortise cut element in the direction of arrow shown above.

Deep Mortise X

Depth parameters

DM Depth: Increasing this parameter will increase the depth of the deep mortise plunge.Z Ech DM Pass: Increasing this parameter will increase the depth of cut for each pass of the deep mor-tise plunge.NOTE: Z Ech DM Pass is factory set to 0.1 inch any adjustment to this parameter may cause difficulty with some cuts.


Parameters

Plate Router

Router Vert Offset (Vertical Offset)

Notes: Increasing the parameter value will move element in the direction of parameter arrow.

3deg Vert (Set Vert Offset first) Vert Offset

Router Diam (Diameter)

Router Diam

Increasing the Router Diam value decreases the size of the Face plate pockets.

Depth parameters

Router Depth: Increasing this parameter will increase the depth of the router plunge.3 Deg Depth: Increasing this parameter will increase the depth of the router plunge in 3 degree mode.Z Each Pass: Increasing this parameter will increase the depth of cut for each pass of the router plunge.



Counter Rotating Router

Cnt Rout Vert, Cnt Rout Horiz (Vertical, Horizontal)


Cnt Rout Vert (Set Router Vert

Cnt Rout Horiz X


Cnt Rout Diam (Counter Router Diameter)

Notes: Increasing the Cnt Rout Diam value decreases the size of the Counter Rotating Router pocket.

Depth parameterCnt Rout Depth: Increasing this parameter will increase the depth of the Counter Rotating Router plunge.


Parameters

Side Drills


Side Drill Y (Set Router VertOffset and 3deg. Vert before

Side Drill X

adjusting this parameter)

Side Drill Z: Increasing this parameter will increase the depth of the Side Drill plunge.Side Drill Diam: Enter the diameter of the side drill bit.

Note: If program calls for a side drill hole size larger than the bit, the machine will use the Deep Mortis router to cut the hole.

Chisels

Note: Increasing the parameter value will move the element in the direction off the parameter arrow.

X Offset to Chisel UL

Y Offset to Chisel UL

Y Offset to Chisel LL

X Offset to Chisel LL

Y Offset to Chisel LR

X Offset to Chisel LR

X Offset to Chisel UR

Y Offset to chisel UR

Z Offset to Chisel aa: Increasing this parameter will increase the depth of the chisel (aa = chisel loca-tion UL, LL, UR, LR).



Predrills

Predrill 1 X offset and Predrill 1 vert offset


Predrill 1 X offset

Predrill 1 vert offset

Depth parameter

Predrill 1 depth: Increasing this parameter will increase the depth of the Predrill 1 plunge.


CHAPTER 11 DL-NCC

This chapter provides operating instructions for the KVAL Architect DLNCC.


DL-NCC


DLNCC - Operator’s Tour

DLNCC - Operator’s Tour

Operators Station:

Start Machine

START

STOP

Disable AutoFeed

Reset Drives Speed ControlFaster

ControlTransformer

Touch Screen

13.8765SEL RES

Cutter MotorCurrent Monitor

Power

• Control Transformer: Applies electrical power to control circuits and computer.• Start Machine: Applies electrical power to drive circuits.• Reset Drives: Resets faulted motor drives.• Speed Control: Selects cutting speed (only affects speed when the cutter is down).• Disable Auto Feed: When ON, it disables the Auto-Feed mode. Motors are still enabled for manual

control.• Cutter Motor Current Monitor: This displays the electrical current drawn by the cutter motor. This

number will vary depending on the material being cut, bit sharpness, cutting speed, motor cooling and motor wear. How to use the current monitor as a dull bit indicator:

1. During normal operation observe and record the current for several doors of each door type (steel, fiberglass, wood, particle board, etc.).

2. Once the normal current has been established for a door type, watch for the current to increase during normal operation.

3.Check the bit for wear. If the bit is still within tolerance (sharp), go back to step 2.4.If the bit is out of tolerance (dull), replace or sharpen it. Then use the last current observed to indicate

a dull bit.


Touch ScreenMain Screen

MANUAL RUN

page 11-10

TOOL CHANGER page 11-8

OFF AUTO FEEDTHRU REVERSE

F E E D M O D E

S E L E C T T O O L

OSCILLATEON

EJECTOFF

RETURNTOOL

Download Received Motor Warm-upMODBUS-MODE

173-SCN1_1v1

100%

DISABLE TOOL

page 11-6

Touch ScreenProgram Version

Feed

Tool

Control

Navigation

Status Indicators

Management

ToolManagement

TOOL-4 TOOL-3 TOOL-2 TOOL-1AVAILABLE SELECTED AVAILABLE DISABLE

STEEL

FIBERGLASS

TOOL-8 TOOL-7 TOOL-6 TOOL-5DISABLE DISABLE SELECTED SELECTED

EMPTY EMPTY DRILL

FIBERGLASS FIBERGLASS FIBERGLASS

Feed OFF AUTO FEEDTHRU REVERSE

• Off: Feed system stops.• Auto: Doors will enter the machine, be processed and sent out with no operator intervention.• Feed Thru: Doors will pass through the machine without being processed.• Reverse: Momentarily reverses the feed direction as long as this button is pushed.


Touch Screen

Automatic Tool Changer

The DL-NCC is equipped with an automatic tool changer. When a door file is downloaded, the DL-NCC determines if a tool change is needed, based on door material defined in the door file. If a tool change is needed, the DL-NCC 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-NCC 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 200* software will display an error message on the Operator’s Station monitor, indicating the problem and how to remedy the problem. If re-calibration is needed, refer to the Tool Changer calibration procedures found on page 6-37.Note: The DL-NCC 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 Disable Tool in the Tool Management section below.the


Tool Tool Type

Tool Type

Tool Status

Tool Status


STEEL

FIBERGLASS


EMPTY EMPTY

Indicator

DISABLE TOOL

page 11-6

DRILL

FIBERGLASS FIBERGLASS FIBERGLASSManagement

The Select Tool portion of this screen displays information pertaining to all tools in the machine. The tool information is organized by the tools position in the tool holder starting from the pivot point out.

• Tool Type: This indicator displays the tool type information from the Calibration file in the DLNCC PC. Available tool types are: steel, fiberglass, drill and other. For more informa-tion on DLNCC calibration see “Calibration” on page 6-37

• Tool Status: These buttons show the current tool status. Pressing these buttons toggles between Selected and Avail-able:-Selected: This tool will be used for the next cut for the given tool type.-Available: This tool is available for use.-Disabled: This tool is unavailable for work. To disable a tool see below.

• Disable Tool:

CLOSEMENU

Tool-4ON

Tool-3OFF

Tool-2ON

Tool-1ON

Tool-8OFF

Tool-7OFF

Tool-6ON

Tool-5ON

DISABLE TOOLSIf all OFF, machine doesnot scan tools on Home

Opens the Disable Tool screen. Pressing the Tool buttons toggles between ON and OFF.-ON: The tool is available for use.-OFF: The tool unavailable.Note: If ALL tools are OFF, the machine will not scan tools when homing.

Example:


FIBERGLASS FIBERGLASS FIBERGLASS FIBERGLASSThe illustration to the right shows tool positions 1 through 4 have been assigned to fiberglass tooling. That tool 1 will not be used, and tool 3 is either in the cutting head, or will be selected by the cutting head before the next cut.

PivotPoint To

ol 1To

ol 2To

ol 3To

ol 4To

ol 5To

ol 6

Tool ChangerAs viewed from the

outfeed end of the machine


Touch Screen

Status indicators: Download Received Motor Warm-up 100%

• Data Transfer Status: Indicates if the DL-NCC has a door file downloaded to it and is available to be run.

• Motor Warm-up: Displays the percentage (%) complete of the warm-up cycle. This reads 100% when the warm-up cycle is complete.

Control:

OSCILLATEON

EJECTOFF

RETURNTOOL

• Oscillate ON/OFF: Manually turns on/off tool oscillation. When on, the cutting tool reciprocates, increasing bit life. NOTE: The reciprocation distance is set in the calibration screen. See “A place-holder for future cross referances.” on page 6-37 for more information.

• Eject ON/OFF: 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.

• Return Tool: This function returns the tool currently in the cutting head it’s place in the tool holder. Note: It is recommended to return the tool to the tool holder at the end of each work day.

NavigationMANUAL

RUN page 11-10

TOOL CHANGER page 11-8

• Tool Changer: Opens the Tool Changer screen. See “Tool Changer” on page 11-8.• Manual Run: Opens the Manual Run screen. See “Manual Run” on page 11-10.


Tool Changer

PREVIOUS MENU

page 11-4

M-2001

M2040

M-2041

M-2042

M-2043

I-41I-42I-43I-44

CR-2001:CUTTER MOTOR

CR-2040:SPEED #1

CR-2041:SPEED #2

CR-2042:SPEED #3

CR-2043:CUTTER WARMUP

CR-41: MOTOR STOPPED

CD-42: ARBOR EXTENDED

I-43: TOOL IN & RETRACTED

I-44: RETRACTED & LOCKED

TOOL CHANGER

8 7 6 5 4 3 2 1Tools Found in Holder

Current Tool In Use 1MOTOR WARM UP

Current Tool Speed 5100%

Move Cutter To Access Location

page 11-9

Start Tool Calibration page 12-1

Navigation

MotorStatus

Tool ChangerStatusMotorStatus

Motor Status

Display Description

These three signal combine to form a binary “word” sent to the motor. This binary word contains the speed selection information. A binary word decoding table is shown below:

Speed 1 Speed 2 Speed 3 Selected Speed01234567

M-2043 = Cutter in warm up mode M-2043 = Cutter not in warm up mode

I-41 = Cutter motor turning I-41 = Cutter motor not turning

I-42 = Cutter motor arbor extended I-42 = Cutter motor arbor retracted

I-43 = Tool detected and in cutter motor tool holder

I-43 = No tool detected and in cutter motor tool holder

I-44 = Tool detected and in cutter motor tool holder

I-44 = No tool detected and in cutter motor tool holder

Displays the percentage (%) complete of the warm-up cycle. This reads 100% when the warm-up cycle is complete.

M-2001 M-2001• Cutter Motor: = Cutter motor is running = Cutter motor is not running

• Speed #1:• Speed #2: • Speed #3:

• Cutter Warm-up:

• Motor Stopper:

• Arbor extended:

• Tool in & Retraced:

• Retracted & Locked:

• Motor Warm Up:


Touch Screen

Tool Changer Status

• Tool Found in Holder: These indicators display the tools sensed by the cutting head calibration eye. In the example below tools tool 1, tool 3, tool 5 and tool 6 where sensed.

PivotPoint

Tool

6To

ol 5To

ol 4To

ol 3To

ol 2To

ol 1

8 7 6 5 4 3 2 1

Tool

8To

ol 7

Tool

1To

ol 2To

ol 3To

ol 4To

ol 5To

ol 6

Tool ChangerAs viewed from the

outfeed end of the machine

• Current Tool in Use: Displays the tool number currently in the cutting head.• Current Tool Speed: Displays the tool speed code entered in the calibration page. See “A place-

holder for future cross referances.” on page 6-37 for more information.

NavigationPREVIOUS

MENU page 11-4


page 11-9

Start Tool Calibration page 12-1

• Start Tool Calibration: Enters the Tool Changer calibration menu. For details on calibrating the Tool Changer, see page 12-1 for more information.

• 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.

• Previous Menu: Displays the previous menu which in the case is the Main menu. See page 11-4 for more information.


Manual Run

PREVIOUS MENU

page 11-4

REVERSE SLOW FORWARD

M A N U A L F E E DDISABLE

AUTO FEED

Download Received MODBUS-MODE

Manual Feed

Navigation

Setup ModeOFFUNCLAMP DOOR

STOP

MANUAL WIDTH ADJUST

JOG JOG

MAINTE-NANCE

TROUBLE SHOOT

JOG CLOSE JOG OPEN

DISABLEAUTO ADJUST

Control

Manual Width Adjust Control

Feed Controls

REVERSE SLOW FORWARD

M A N U A L F E E D DISABLEAUTO FEEDJOG JOG

• Jog Reverse: Moves the feed in the reverse direction.• Fast: Pressing this button in conjunction with Jog Reverse or Jog Forward puts the feed in fast

mode. • Jog Forward: Moves the feed in the forward direction.• Disable/Enable Auto Feed: Enable or disable auto-feed feature. If enabled, the auto-feed system

operates normally. If disabled, the feed system must be operated manually.

• Width Adjust Controls

Setup ModeOFFUNCLAMP DOOR

STOP

MANUAL WIDTH ADJUST

JOG CLOSE JOG OPEN

DISABLEAUTO ADJUST

• Jog Close: Manually closes the width adjust.• Jog Open: Manually opens the width adjust. • Disable/Enable 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.

• Clamp/Unclamp: Toggles door clamp between clamped and unclamped. • Door Stop: Toggles door stop between up and down.• Setup Mode ON/OFF: 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.


Touch Screen

NavigationPREVIOUS

MENU page 11-4

MAINTE-NANCE

TROUBLE SHOOT

• Trouble Shooting: Opens the trouble shooting menu.• Maintenance: Opens the Maintenance menu• Previous Menu: Returns to the previous menu


Changing a Tool Manually

For normal operations, the tool is changed automatically, where the DL-NCC is programmed inthe Door File to select the tool appropriate to the door material. However, you can manuallychange the tool if you wish (for example, to change a dull bit, if there is a mechanical problemwith 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 DLNCC” on page 11-17 for instructions.

1.

While holding the toolwith the other hand, pullthis button to release thetool from the motor.

Grasp the toolfirmly by the collet.

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.

!

!


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).

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 col-

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

Tool (assembled) Tool (fully disassembled)

ColletAssembly

Bit

Collet

ColletHousing

Collet Nut


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 sur-face and the bottom of the collet is 1-1/16 inches.

1-1/16”

6.As shown in the illustration below, use the open-end wrench to hold the collet in place and use the col-let wrench to tighten the bit firmly in the collet.


Homing the DLNCC

Homing the DLNCCThe DLNCC 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 Face mea-sures its motion when making cuts.You should home the DLNCC:


To Home the DLNCC

1. Remove any doors from the feed system.2. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button

below it to read Home.3. Click twice on the Home button. The Face should start the homing operation.

NOTE:While the homing operation is in progress, the Home button changes its label to Homing.


CHAPTER 12 Calibrating the DL-NCC

This section provides detailed procedures for calibrating the Tool Changer (see below) and for calibrat-ing the cut accuracy (see “Calibrating Cut Accuracy” on page 12-14).Note: If, after making the initial calibrations, you discover cut inaccuracy, refer to the streamlined rem-edy procedures in the Troubleshooting chapter (see “Correcting Cut Accuracy Problems” on page 12-17).

Calibrating the DL-NCC Tool Changer

The tool changer must be calibrated to make sure the DL-NCC 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 (page 12-3)• Tool Calibration, Stage 2: Tool Offset (page 12-8)• Tool Calibration, Stage 3: Tool Holders (page 12-12)

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 Calibra-

tion 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.


Calibrating the DL-NCC

2.

PREVI-OUS

MENU

M-2001

M2040

M-2041

M-2042

M-2043

I-41I-42I-43I-44


CR-2040:SPEED #1

CR-2041:SPEED #2

CR-2042:SPEED #3






TOOL CHANGER





Start Tool Calibra-

tion

PREVIOUS MENU

TOOL LOCATION CALIBRATION

STAGE 1 page 12-3

STAGE 2 page 12-8

STAGE 3 page 12-12

Set Location of calibration bolt

Determine distance betweeneye and cutter head

Position tool holders

MANUAL RUN

TOOL CHANGER


F E E D M O D E

S E L E C T T O O L

OSCILLATEON

EJECTOFF

RETURNTOOL


173-SCN1_1v1

100%

DISABLE TOOL


STEEL

FIBERGLASS


EMPTY EMPTY DRILL


Access the Tool Changer screen on the Touchscreen interface. To access the Tool Changer screen:

a.From the Main menu press Tool Changer.b.On the Tool Changer menu press Start Tool Calibration.

3.After you access the Tool Calibration screen, proceed to the calibration proce-dure prescribed by the Determining Which Calibration Stage to Use guide-lines on page 12-1. • Stage 1: go to page 12-3. • Stage 2: go to page 12-8. • Stage 3: go to page 12-12.


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.

Tool Change Error. Calibration Bolt Not Aligned.[Click to Clear]

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.

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 Disable Tools pop-up screen shown above.

3.Home the machine. For instructions, see “Homing the DLNCC” on page 11-17.

MANUAL RUN

TOOL CHANGER


F E E D M O D E

S E L E C T T O O L

OSCILLATEON

EJECTOFF

RETURNTOOL


173-SCN1_1v1

100%

DISABLE TOOL


STEEL

FIBERGLASS


EMPTY EMPTY DRILL


CLOSE-MENU

Tool-4OFF

Tool-3OFF

Tool-2OFF

Tool-1OFF

Tool-8OFF

Tool-7OFF

Tool-6OFF

Tool-5OFF

DISABLE TOOLSIf all OFF, machine doesnot scan tools on Home

Main Menu

Disable Tools Pop-up



4.Navigate to the main Tool Calibration screen (for navigation help, see page 12-2) and press the Stage 1 button to access the Stage 1 screen.

PREVIOUS MENU


STAGE 1

STAGE 2

STAGE 3




Tool Calibration Screen

Tool Calibration Stage 1 screen

PREVIOUS MENU

Tool Location Calibration Stage 1

Toggle Head Position

Calibration Bolt

BetweenOver Calibration Bolt andAway from Calibration Bolt

ToggleHead Position

HELP

5.ToggleHead Position

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.


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


7.Maint

Cal

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.

Calibration and Jog will Abort ProgramHit Esc or exit to cancel

[Click to Clear]

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

X

X Axis Y Axis Z AxisJog X Y and Z


4000 4000 4000

EXIT

Setup

Calibration

Galil


[Space Bar to Stop]

Calibration Menu

10.Calibration Click the Calibration button. This takes you to the calibration pages where the calibration takes place. The first page displayed is Calibration Page 1:

X

EXIT

Protection Cal

Jog Menu

Galil

Calibration Page 1

Page Up

Page Down

DoorNum.dbf List1) 618 Door Count=6182) Face 14) Face 26) Face 38) Face 410) Edge 112) Edge 214) Edge 316) Archdidm718) Archdi420) A,26 (5)

- Stop Location Calibration (X-Axis)Primary Infeed Stop(1) .646 + 0 = 0.646

Primary Outfeed Stop(1) 106.692 + 7.312 =114.004

- Cutter Head Calibration Values (Y Axis)Y Calibration(1) .265 + 0 = .265

- Cutter Depth Calibration (Z Axis)Cutter Plunge Depth Cal(1) 0 + 0 = 0.000

Cutter Max Plunge Cal 1.00 + 0 =1.000Shallow Cut Depth Cal .25 + 0 = .250

Slow Plunge Speed Factor .020 + 0 = .020



11.Page Up

Click the Page up button once to access Calibration Page 2 (Tool Changer Calibration):X

EXIT

Protection Cal

Jog Menu

Galil

Calibration Page 2

Page Up

Page Down


- Width Adjust CalibrationWidth Adjust Calibration(1) .250 + 0 = .250

Width Adjust Tolerance(1) 0.50 + 0 =.500Width Open After Unclamp(1) .949 + -.400 =.549

-Tool Changer CalibrationTool Alignment Bolt X(1) 120.076 + 0 =120.076Tool Alignment Bolt Y(1) 37.411 + 0 =37.411

Tool Location Offset X(1) 2.855 + 0 =2.855Tool Location Offset Y(1) 15.237 + .031 =15.268Tool Location Offset Z(1) 0.000 + .062 =.062

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-NCC), 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:

c.Type the offset in the right-hand field, press the Enter key, and then click the leftmost 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.

98.815 + 2.180 =100.693 (Modifier field has a non-zero value)

98.815 + 2.180 =100.693 (Click on the left-most field)

100.693 + =100.693 (Offset is updated, Modifier field is empty)

X


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:

-Tool Changer CalibrationTool Alignment Bolt X(1) 97.584 + -0.250 = 97.584

Press the Enter key.

-Tool Changer CalibrationTool Alignment Bolt X(1) 97.584 + -.250 = 97.584

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

-Tool Changer CalibrationTool Alignment Bolt X(1) 97.334 + = 97.584

14.If the Calibration Eye is out of alignment along the Y axis (across the width of the DL-NCC machine), adjust the Tool Alignment according to the following sub-procedure. If there is no misalign-ment 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 12-6).c.Type the offset in the right-hand field, press the Enter key, and then click the leftmost 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 Cali-bration 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-NCC detects misalignment between the Eye and the Bolt, the KVAL 2006 Interface will dis-play the following alert:

Tool Change Error. Calibration Bolt NotAligned.[Click to Clear]

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.

Tool Alignment Bolt Y(1) 37.573 + 0 = 37.573



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:

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.

MACHINE

START

STOP

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 by the collet).

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

ii) 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 spin-dle.iii) Once the tool is released from the motor, slide it down and away from the motor. Set the old tool aside.iv) Push in the black Tool Release button.v) Insert tool into the proper tool holder.

MANUAL RUN

TOOL CHANGER


F E E D M O D E

S E L E C T T O O L

OSCILLATEON

EJECTOFF

RETURNTOOL


173-SCN1_1v1

100%

DISABLE TOOL


STEEL

FIBERGLASS


EMPTY EMPTY DRILL


PREVI-OUS

MENU

M-2001

M2040

M-2041

M-2042

M-2043

I-41I-42I-43I-44


CR-2040:SPEED #1

CR-2041:SPEED #2

CR-2042:SPEED #3






TOOL CHANGER





Start Tool Calibra-

tion

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

While holding the toolwith the other hand, pullthis button to release thetool from the motor.

Grasp the toolfirmly by the collet.


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.

3.Home the machine. For instructions, refer to “Homing the DLNCC” on page 11-17.NOTE: The homing procedure will produce the following error:

No Tool In Cutter Head Warm-up Not Started

[Click to Clear]

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 12-2) and press the Stage 2 button to access the Stage 2 screen.

PREVIOUS MENU


STAGE 1

STAGE 2

STAGE 3






PREVIOUS MENU


Toggle Head Position

Tool Offset

BetweenCalibration and Tool 1

ToggleHead Position

HELP


Press the Toggle Head Position button one time and verify that the machine responds as follows:

Motor is positioned over the center of Tool #1

• 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.


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.

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-NCC) and the Y axis (width of DL-NCC). Then proceed to the next step.



8.Maint

Cal




[Click to Clear]


X

X Axis Y Axis Z AxisJog X Y and Z


4000 4000 4000

EXIT

Setup

Calibration

Galil


[Space Bar to Stop]

Calibration Menu


X

EXIT

Protection Cal

Jog Menu

Galil

Calibration Page 1

Page Up

Page Down









12.Page Up

Click the Page up button once to access Calibration Page 2 (Tool Changer Calibration):X

EXIT

Protection Cal

Jog Menu

Galil

Calibration Page 2

Page Up

Page Down


- Width Adjust CalibrationWidth Adjust Calibration(1) .250 + 0 = .250

Width Adjust Tolerance(1) 0.50 + 0 =.500Width Open After Unclamp(1) .949 + -.400 =.549

-Tool Changer CalibrationTool Alignment Bolt X(1) 120.076 + 0 =120.076Tool Alignment Bolt Y(1) 37.411 + 0 =37.411

Tool Location Offset X(1) 2.855 + 0 =2.855Tool Location Offset Y(1) 15.237 + .031 =15.268Tool Location Offset Z(1) 0.000 + .062 =.062

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-NCC), adjust the Tool Loca-tion 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 12-6).c. Type the offset in the right-hand field, press the Enter key, and then click the leftmost 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 pro-cess is illustrated below:

Tool Location Offset(1) 3.257 + 0.250 = 3.257

Press the Enter key.Tool Location Offset(1) 3.257 + 0.250 =3.507

Click the left-hand field (updates with final offset value).Tool Location Offset(1) 3.507 + = 3.507

14.If the cutter motor is out of alignment along the Y axis (across the width of the DL-NCC 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 12-6).c.Type the offset in the right-hand field, press the Enter key, and then click the leftmost

Tool Alignment Bolt Y(1) 37.573 + 0 = 37.573



d.Type the offset in the right-hand field, press the Enter key, and then click the leftmost 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.EXIT When you are finished making the calibration adjustments, click the Exit button. This exits the Cal-ibration 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.Note: Tool Location Offset Z(1) is factory set, adjustment should be unnecessary.

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.

MACHINE

START

STOP

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 12-3.


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 but-ton. 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 DLNCC” on page 11-17.9. 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.

PREVIOUS MENU


STAGE 1

STAGE 2

STAGE 3






PREVIOUS MENU


This Mode is Used

Tool Holders

To Adjust Tool Holders

NextStep

HELP

10.NextStep

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.

Tool Release button



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 on the PC, press ABORT , then Restart .e.Next

Step 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-NCC needs to be calibrated so that the cuts and holes are started at the correct X and Y coordi-nates.

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).

Primary Stop

X = 10”

Y = 10”5”X5” cut

Lock Side

Hinge S

ide

FeedDirection

Top of Door

Secondary Stop

X = 10”

Y = 10”5”X5” cut

Lock

Sid

e

Hin

ge S

ide

FeedDirection

Top of DoorStep 1 Cut Step 2 Cut

X Location 10.000Y Location 10.000Length 5.000Width 5.000


3.If there are inaccuracies in the cuts, adjust the calibration settings:4.Maint

Cal




[Click to Clear]


X

X Axis Y Axis Z Axis

Jog X Y and Z


4000 4000 4000

EXIT

Setup

Calibration

Galil


[Space Bar to Stop]

Calibration Menu


X

EXIT

Protection Cal

Jog Menu

Galil

Calibration Page 1

Page Up

Page Down










8.If there is inaccuracy in the X coordinate for cuts on an LH door, adjust the Primary Stop setting. Oth-erwise, skip to Step 9.

a. Locate the Primary Stop-Outfeed(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, page 12-6).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 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. inch toward the top of the door, type g-1/4h or g-0.250h in the field and press the Enter key. Then click the left-most field to record the offset value.

This process is illustrated below:-Stop Location Calibration (X-Axis)

Primary Stop-Outfeed(1) .171 + -0.250 = .171

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

-Stop Location Calibration (X-Axis)Primary Stop-Outfeed(1) .079 + = .079

9. If there is inaccuracy in the X coordinate for cuts on an RH door, adjust the Secondary Stop setting. Otherwise, skip to Step 10.

a. Locate the Secondary Stop-Outfeed(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.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 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 8-c above)

10.g. If there is inaccuracy in the Y coordinate for the cut, adjust the Y Calibration setting. Otherwise, skip to Step 11.

a. Locate the Y Calibration(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.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 cut needs to move toward the fixed fence of the DL-NCC, enter a negative value. If the cut needs to move away from the fixed fence of the DL-NCC, enter a pos-itive value. (see example in Step 8-c above)

11.EXIT When you are finished making the calibration adjustments, click the Exit button. This exits the Cal-ibration page and the KVAL 2006 program.

12. Re-launch the KVAL 2006 program.13. Click on the Abort button, then the Load Programs button at the bottom right corner of the

KVAL 2006 program screen.

Secondary Stop-Infeed(1) 98.180 + 0 = 98.180

-Cutter Head Calibration (Y and Z Axis)Y Calibration 0.000 + 0 =0.000


14. 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: • 8 inches from the top (X) and 8 inches from the side (Y) X Location 8.000

Y Location 8.000Length 9.000Width 9.000

• 9 inches long and 9 inches wide15. If there are inaccuracies in the cuts, adjust the calibration settings accordingly

(refer back to Step 3 above), and then redo the validation.

Correcting Cut Accuracy Problems

For full details on calibrating the cut accuracy, refer to the procedure on page 12-14.

Cut Accuracy Problems DescriptionCut 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 Second-ary 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 Cali-bration(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.


CHAPTER 13 RAIL

This chapter provides operating instructions for the KVAL Rail.


RAIL


Door Stack Access

Door Stack AccessThis Rail is equipped with Light Curtain safety devices. Breaking the light curtain beam has the same result as pushing an E-Stop. Power is removed from all motors, all servo systems, and all control cir-cuits. When enabled, the Light Curtains do not allow access to the door stacks. To enable access to the door stacks use the Door Stack Access Mode procedure shown below.

To Enable the Door Stack Access Mode:Light Curtain

Stack Access Area

Light Curtain

Stack Access Area

(RED) (RED)

(YELLOW) (YELLOW)

1.Press the Enable Access button.2.Wait for the Enable Access button and the blue light tower light to flash on and off.3.The Stack Area is available for access.

With Safety Skirt, Entry OK No Safety Skirt, No Entry

CAUTION: At this point there is still power to all motion control systems. • Do not enter the machine any further than the

stack access area indicated in yellow above.• Keep away from the door lift and the vacuum

clamp.• The lift must be equipped with a safety skirt. Do

not enter the stack access area if the safety skirt has been removed.

CAUTION: The Door Stack Access Mode allows access behind the machine’s light curtain safety devices and is for loading and unloading the door stacks ONLY. No maintenance should be performed in this mode. All controlling outputs are frozen. However, POWER IS STILL APPLIED TO ALL MOTION CONTROL SYSTEMS. In this mode a system failure could cause a motion control system to “run away” at full speed. DO NOT PUT YOURSELF IN A MOTION CONTROL SYSTEM’S PATH.

USE EXTREME CAUTION WHEN enabling the Door Stack Access Mode.


To Disable the Door Stack Access Mode.

1.Ensure all personal are away from the machine and outside the light curtain.1.Pull out the Enable Access button.

The Enable Access button and the blue light tower light should turn off.The machine is now ready to resume work.


Rail - Operator’s Tour

Rail - Operator’s Tour

Infeed End

Outfeed End

FeedDirection

Top View

Alliance Series - Rail 13-5

Operators Station:

Touch Screensee page 13-7

Control Panel

Control Panel

Control Transformer(Maintained)

PushOff

PullOn

MACHINE

START

STOP

Speed Select

70%80% 90%

100%

Router Depthof Cut

1.01.5 2.0

2.5

Faster

Reset Drives Disable Cycle(Maintained)

Vacuum

Off On

Control Panel

• Control Transformer: Applies electrical power to control circuits and computer

• Machine START STOP: Applies electrical power to drive circuits.

• Vacuum: Controls the Vacuum Clamp’s vacuum.• Speed Select: Sets the cutting speed. Use higher

settings for soft material, slower settings for hard material. If the speed ranges are not adequate for you needs please contact KVAL service.

• Reset Drives: Resets the motor drives.• Router Depth: Sets the depth of cut for each

router pass.• Disable Cycle: Stops the current lift and roll table

process.


Touch Screen

Touch ScreenOK to Home

-12.452FORKLIFT00:NOT HOMED

I-41 RDY

CMD ACK12.73 11.50

112.327CARRIAGE00:NOT HOMED

I-40 RDY

CMD ACK09.13 10.52

107.022STOP00:NOT HOMED

I-42 RDY

CMD ACK06.24 05.48

MANUAL MODE

page 13-8O.K. TO HOME

Forklift StatusMessages

Carriage StatusMessages

Feed table StopMessages

Navigation & Control

• Manual Mode: Opens the Manual Mode screen. See page 13-8 for more details.• O.K. to Home: Starts the homing process.

The OK to Home button has three states:Yellow = OK to HomeRed = Unable to home. The ON2010 has found a condition that prohibits it from homing. Green = Homed.


Main Menu REMOTE

MAINTE-NANCE

page 13-18

GO TO LOCAL

page 13-10

RESET

MB: OK

AUTOFEED

123.454

NO ACCESS

12.545117.352096.135

FORKCARRSTOPMB-DL

RDYRDYRDY

LIFT#1: ON

LOAD POS

PICK-UP

LOAD-POS

PICK-UP

STACK#2

STACK#1

STACK XFER2 -> 1

Stack Control

LASTDOOR Navigation

Feed Control

Feed Control

Toggles Auto Feed between ON and OFF.

When a door tagged as 'Last Door” enters the Rail machine no other doors are allowed into the rail. Pushing this button allows processing to continue.

Stack Control

STACK#2

STACK#1

Selects Stack #2 Selects Stack #1

LOAD POS

PICK-UP

Holding this button will


raise the selected stack.

lower the selected stack.

AUTOFEED

RESETLASTDOOR


Touch Screen

• Stack Transfer (STACK XFER)

STACK XFER2 -> 1

The Stack Transfer button (STACK XFER) allows doors to be moved from Stack #2 to Stack #1.Unload Doors

Here

From Previous

STACK XFER2 -> 1

Remove DoorsHere

Remove Doors Here

STACK XFER2 -> 1

STACK XFER2 -> 1

Stack Transfer ONStack Transfer OFF

Machine

MAINTE-NANCE

page 13-18

GO TO LOCAL

page 13-10

Navigation

• Go To Local: Opens the Main Menu LOCAL scree. See page page 13-10 for more information. • Maintenance: Opens the Maintenance screen. See page 13-18 for more information.


Main Menu LOCAL

READY

MB: OK123.454 NO ACCESS

12.545117.352096.135

FORKCARRSTOPMB-DL

RDYRDYRDY

LIFT#1: ONENTER-DATA

MAINTE-NANCE

page 13-18

GO TO REMOTE page 13-8

AUTOFEED

LOAD POS

PICK-UP

LOAD-POS

PICK-UP

STACK#2

STACK#1

STACK XFER2 -> 1

Stack Control

NavigationFeed Control

Door LengthEntry

DOORLENGTH

72.2596.0060.25

110.75

DOOR LENGTH PRESET EDIT

Door Length Entry

Door Length Select:Steps through the four Door Length Presets

Doo

r Len

gth

Doo

r

Door Length Preset Edit:

Allows editing of door length preset values. For more information see “How to change a door length preset:” on page 13-11

DOORLENGTH

72.2596.0060.25

110.75

DOOR LENGTH PRESET EDIT

• Door Length Preset Edit:

40.25

SAVE & EXIT

PREVIOUS MENU

7 8 9

4 5 6

1 2 3

0 DEC(.)

FRC(/)

CLR

ENTER[DL-1]

DOOR-WIDTH 64.75 96.00 72.25110.75

DOOR-LENGTH-1DL-1DL-2DL-3DL-4

60.2596.0072.25

110.75

PRESET NEW

MAX. DOOR-LENGTH = XX.XX

DOOR LENGTH PRESET EDIT The Door Length Preset Edit

button Calls the Door Length Edit screen shown below. Use this screen to modify the door four length presets.


Touch Screen

How to change a door length preset:

1.Use the Door Length Preset selector button to scroll to the desired preset.

DOOR-LENGTH-1DL-1DL-2DL-3DL-4

2.Use the Key Pad to enter the new door length preset value. The keyed in value will appear in the Key Pad Display. Fractional values can be entered as decimal number or fractions (see page 13-12). The value entered must be less than the Max. DOOR-LENGTH value displayed to the right of the key pad.Note: To clear a value press the CLR (clear) button.

64.75

7 8 9

4 5 6

1 2 3

0 DEC(.)

FRC(/)

DOOR-LENGTH

CLRKey Pad

Key PadDisplay

ClearButton

3.After the new value has been keyed in press the Enter key. This will load the keyed value into the “New” section of the display.

ENTER[DL-1]

64.75

7 8 9

DOOR-LENGTH 64.75 96.00 72.75110.75

NEW

4.Save or discard changes: 64.75 96.00 72.75110.75

PRESET

PREVIOUS MENU

Exit with

64.75 96.00 72.75110.75

DL-1DL-2DL-3DL-4

NEW

SAVE & EXITExit and

no Change Save New values

• Save and Exit will save the values displayed in the “New” section of the display as door width preset values.

• Previous Menu will exit leaving the “Preset” values as door width preset values.


Entering Fractional Values:

For decimal mode enter the number using the Decimal Point key.

For fractional input enter the whole number then press the Fraction Key.

The Fractional Key displays the screen shown to the right. When a Fractional key is pressed the value is displayed is shown in thirty seconds of an inch. For example if 1/4 is pressed, 08/32 will be displayed.When the correct value has been entered press previous menu to return to the previous screen.

Feed Control

Toggles Auto Feed between ON and OFF.

Stack Control

STACK#2

STACK#1


LOAD POS

PICK-UP





DEC(.)

FRC(/)

[11/32] 42.34375

1/32 1/16 3/32 1/8 5/32 3/16 7/32 1/4

9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2

17/32 9/16 19/32 5/8 21/32 11/16 23/32 3/4

25/32 13/16 27/32 7/8 29/32 15/16 31/32

42

PREVIOUS MENU

Whole Number Fractional Number

AUTOFEED


Touch Screen

• Stack Transfer (STACK XFER)

STACK XFER2 -> 1

The Stack Transfer button (STACK XFER) allows doors to be moved from Stack #2 to Stack #1.Unload Doors

Here

From Previous

STACK XFER2 -> 1

Remove DoorsHere

Remove Doors Here

STACK XFER2 -> 1

STACK XFER2 -> 1

Stack Transfer ONStack Transfer OFF

Machine

MAINTE-NANCE

page 13-18

GO TO REMOTE page 13-8

Navigation

• Go To Remote: Opens the Main Menu Remote screen. See page 13-8 for more information. • Maintenance: Opens the Maintenance screen. See page 13-18 for more information.

Ready Enter Data

READYENTRYDATA

Press this button to start the process after the door data, and the door have been entered into the machine.


How to Run a Door in Manual Local Mode:

1.Load the door or doors into the machine.2.Select the Stack

STACK#1

STACK#2

3.Raise the stack to clamp-ing height.

PICK-UP

4.Select the door length. DOORLENGTH

5.Select the ModeSTACK XFER

2 -> 1

STACK XFER2 -> 1

Stack Transfer OFF

or

Stack Transfer ON

6.

READYENTRYDATA

Press Ready Enter-Data to start the process.


Touch Screen

Manual Mode

PREVIOUS MENU

page 13-7

FORKLIFT SERVO

MANUALCROSSFEED-REV

CARRIAGE SERVO

102.28176

CLAMP

UP

UP

DOWNSTACK#1

LIFT

UP

DOWNSTACK#2

LIFT

STOP SERVO

123.45758

104.92365

DOWN

MANUALFEED-REV

IN OUT

#2 #1

RESETSEQUENCE

This screen give manual control to the operator.

Reset Sequence:

Use this button to return the ON-2010 back to a known state after any manual move.

Forklift Servo:

Holding this button will move the Forklift up.

Holding this button will move the Forklift down.

Stop Servo:

Holding this button will move the Stop toward the infeed end of the machine.

Holding this button will move the Stop toward the outfeed end of the machine.

RESETSEQUENCE

UP

DOWN

IN

OUT

Infeed End

Outfeed End

Stop

In

Out


Carriage Servo:

Holding this button will move the Car-riage and Vacuum Clamp toward stack 2.

Holding this button will move the Car-riage and Vacuum Clamp toward stack 1.

Stack Control

Stack #2 Stack #1

Holding this button

Holding this button

will raise the stack.

will lower the stack.

UP

DOWNSTACK#1

LIFT

UP

DOWNSTACK#2

LIFT

• CLAMP UNCLAMP : This button toggles between, Clamp (Red) and Un-Clamp (Green).

When the button is Green the vacuum is applied to the Vacuum Clamp. When the button is Red, the Vacuum is removed from the Vacuum clamp.

Feed

• MANUALFEED-REV

Reverse Feed Direction

Reverse feeds the door on the roll table.

#2

#1

Infeed End

Outfeed End

Stack#2

Stack#1


Touch Screen

• MANUALCROSSFEED-REV

Reverse Crossfeed Direction

Reverse feeds the door on the cross feed system.

Navigation:

• Previous Menu: Opens the previously opened screen.


Maintenance -1

PREVIOUS MENU

page 13-8

FORKLIFTCHANGE

NEXT PAGE

page 13-19

MANUAL MODE

page 13-15

MODBUSMODE 172-SCN1_1v1

POSITIONCARRIAGECHANGEPOSITION

PLC

STOPCHANGEPOSITION

PLCINPUT-

OUTPUT

PLCTIMER

STATUS

PLCH-BIT

STATUS

SCRIPT& DRIVESTATUS

D1900-00D1900-01D1900-02D1900-03D1900-04D1900-05D1900-06

D1950.00D1950.01D1950.02D1950.03D1950.04D1950.05

Port-1MODE

D1900-11D1950.06

D1900-12D1950.07

D1900-13D1950.08

XX.XXX.X

XX.XXX.X

XX.XXX.X

MB STATUS[SERVO-PLC]

Machine Data

page 13-22

REMOVE DOOR

page 13-20

ModBus comm.

Touch Screen

Navigation

Status: Lift toLift to Rail

Programversion

Servo

ModBus

PositionPoints

Commmode

and Trouble-shooting

Servo Position Points:

• Forklift Change Position: Displays the Forklift Change Position menu. Parameters on this screen are factory set and should need no modification.

• Carriage Change Position: Displays the Carriage Change Position menu. Parameters on this screen are factory set and should need no modification.

• Stop Change Position: Displays the Stop Position menu. Parameters on this screen are factory set and should need no modification.

ModBus Communication mode:

MODBUSMODE

PROG.MODE

Normal Mode Program Mode

Toggles between normal and program mode. For normal operation this button must be in normal mode.

ModBus Communicating Status: Lift to Rail

Displays the status of the ModBus communication bits between the Lift PLC and the Galil motion control board. This display is designed to assist in trouble shooting the machine.

Touch Screen Program Version

This displays the program version loaded in the touchscreen. Have this number available when con-tacting KVAL for troubleshooting assistance.


Touch Screen

PREVIOUS MENU

page 13-8

NEXT PAGE

page 13-19

MANUAL MODE

page 13-15

PLCINPUT-

OUTPUT

PLCTIMER

STATUS

PLCH-BIT

STATUS

SCRIPT& DRIVESTATUS


Machine Data

page 13-22

REMOVE DOOR

page 13-20

Navigation

• Manual Mode: Opens the Manual Mode screen. See page 13-15 for more information. • Machine Data: Opens the Machine data screen. See page 13-22 for more information.• Remove Door: Opens the Remove door screen. See page 13-20 for more information.• Next Page: Opens the second maintenance page. See page 13-8 for more information.• Previous Menu: Opens the previously opened screen.

Troubleshooting

PREVIOUS MENU

page 13-8

NEXT PAGE

page 13-19

MANUAL MODE

page 13-15

PLCINPUT-

OUTPUT

PLCTIMER

STATUS

PLCH-BIT

STATUS

SCRIPT& DRIVESTATUS


Machine Data

page 13-22

REMOVE DOOR

page 13-20

These buttons open the trouble shooting. Troubleshooting goes beyond the scope of this manual.

Maintenance -2

PREVIOUS MENU

page 13-18

12

12

CONTRAST LEVEL (0 - 31)

COLOR BRIGHT-NESS (0 - 31)

Touch Screen view adjustments:

• Color Brightness: Adjusts the touch screen’s brightness. • Contrast Level: Adjusts the touch screen’s contrast level.

Navigation:

• Previous Menu: Opens the previous screen.


Remove Door

M-190M-191M-192M-193M-194

MANUALFEED

REVERSE

PREVIOUS MENU

page 13-19

NO ACCESS

STACK#1LOAD POS

PICK-UP

STACK#2LOAD POS

PICK-UP

RESETSEQUENCE

STACK#1

MANUALCROSSFEED

REVERSE

MANUALCROSSFEEDFORWARD

MANUALFEED

FORWARD

DOOR NOTIN POSITION

AUTOFEED

CLAMP

STACK#2

D1950-02D1950-04D1950.05D1950.06D1950.07D1950.08

D1950-00D1900-00D1900-02D1900-04D1900-05D1900-06

MB:OK

Feed

Homing Status andStart Button

Clamp: ManualOperation

Stack Control

ResetSequence

NavigationOpens Previous

Menu

Feed

•

Reverse Feed Direction

MANUALFEED

REVERSE

MANUALFEED

FORWARD


Forward feeds the door on the roll table.

Forward Feed Direction

Infeed End

Outfeed End

Feed Table.

ReverseCrossfeed

MANUALCROSSFEED

REVERSE

MANUALCROSSFEEDFORWARD


Forward feeds the door on the roll table.

Direction

ForwardCrossfeedDirection

Infeed End

Outfeed End

Cross feed system.


Touch Screen

Clamp: Manual Operation

CLAMP CLAMPUN-

This button toggles between, Clamp (Red) and Un-Clamp (Green). When the button is Green the vacuum is applied to the Vacuum Clamp. When the button is Red, the Vacuum is removed from the Vacuum clamp.

Homing Status and Start Button

DOOR NOTIN POSITION

OK TO HOME HOMING ALL HOMEDHOMING

DISALBLEDXXXXX

The Homing Status and start button when pressed, starts the homing process. I also shows the current status of the homing process:

• OK to Home: The machine and door in the machine are in the correct position for homing.• Homing: Homing is in process.• All Homed: The homing process is finished.• Door Not in Position: The machine has detected a door on the cross feed system.

Note: In order to Home move the door into the End Mill section of the machine using the Manual Crossfeed Forward button on the touch screen. The door must contact the End Mill Door Stop. For more information see step 6. on page 13-14 under How to Manually remove uncompleted doors from the line:

• Homing Disabled: The machine is unable to home. The reason will also be stated.

Stack Control

STACK#2

STACK#1


LOAD POS

PICK-UP





Reset Sequence:

Use this button to return the ON-2010 back to a known state after any manual move. RESET

SEQUENCE


Machine Data

MACHINE DATAMACHINE TOTAL

DAILY TOTAL

1,004,576

842

RESET PREVIOUS MENU

page 13-19DAILY

• Machine Total: Displays the count of completed milling cycles.• Daily Totals: Displays the total number of milling cycles completed since Reset Daily was pushed.• Reset: Resets Daily Totals to 0.• Previous Menu: Returns to the previous menu.

Technical Support

Previous Screen

page 13-19

TECHNICAL SUPPORT4:00 A.M to 4:30 P.M. (PACIFIC TIME)

MONDAY through FRIDAYPH: 800-553-5825

This screen displays KVAL’s support contact information. For more information visit www.kvalinc.com.


Homing the RAIL

Homing the RAILThe Rail 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 Rail measures its motion when making cuts.You should home the Rail:


To Home the Rail

The Rail machine has two sections, a door stacker and an end mill. Each section requires it’s own hom-ing routine.1.Homing the End Mill section of the Rail:

a. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.b. Click the Home button. This will change the button label to OK to Home?c.CLick the OK to Home? button.d.NOTE:While the homing operation is in progress, the Home button changes its label to Homing.

2.Homing the Door Stacker section of the Rail:a.On the touch screen Press OK to HOME.

Note: If there is a door in the Rail machine see step 6. under “How to Manually remove uncompleted doors from the line:” on page 1-16.

Maint

Home

OKHome?

Homing

O.K. TO HOME


CHAPTER 14 Calibrating the RAIL

Coming Soon


Calibrating the RAIL


alliance series operating instructionsoperating instructions. face. for small complex cuts on a...

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