Kval DL-2DH Operation manual

Innovation, Quality & Honesty
Operation and Service Manual
Published: 4/28/16
DL-2DH Door Light Cut-Out Machine
DL-2DH Door Light Cut-Out Machine

KVAL DL-2HD Operation/Service Manual
Proprietary Notice
This Manual is confidential and contains proprietary information and intellectual
property of KVAL Inc., and is to be used solely by Customer as an operating manual
for KVAL Inc. machines. Neither this Manual nor any of the information contained
herein may be reproduced or disclosed under any circumstances without the express
written permission of KVAL Inc. For authorization to copy this information, please
call Kval Customer Support at [phone] or fax [phone]. Outside the
U.S. and Canada, call [phone].
Manual Part Number: 126_OPSRV_DL2_V1
The DL-2DH Door Light Cut-Out System is a trademark of Kval Incorporated.
Copyright Kval Incorporated. All rights reserved.
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rated products, contact the Customer Support Department
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Kval Incorporated
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Petaluma, CA 94952
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• Business hours:
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• Email: [email protected]

KVAL DL-2HD Operation/Service Manual
KVAL DL-2HD Operation/Service Manual
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KVAL DL-2HD Operation/Service Manual

KVAL DL-2DH Operation/Service Manual
Table of Contents
Chapter 1 Introduction to the DL-2DH
Chapter 1 at a Glance.............................................................. 1-1
Overview of the DL-2DH.......................................................... 1-2
Options Available..................................................................................1-3
About this Manual.................................................................................1-4
Safety Sheet Sign-Off Sheet.................................................................1-4
Safety First!.............................................................................. 1-5
Safety Sheet Sign-Off Sheet.................................................................1-5
Safety Terminology of Labels................................................................1-5
Safety Guidelines..................................................................................1-5
Lockout-Tagout Guidelines...................................................... 1-9
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9
Lockout Tagout Procedure....................................................... 1-10
Pre-Steps Before Lockout Tagout.......................................................1-10
Lockout Tagout Power........................................................................1-10
Lockout Tagout Air Supply..................................................................1-11
Start Maintenance...............................................................................1-11
Post Maintenance Steps.....................................................................1-11
Zero-Energy to Start-Up........................................................... 1-12
Getting Help from KVAL........................................................... 1-14
On-Line Help.......................................................................................1-14
Product Return Procedure..................................................................1-14
How to Download the Service Application............................... 1-16
Download Application.........................................................................1-16
Safety Sign-Off Sheet.............................................................. 1-19
A Note to the Operator........................................................................1-19
Chapter 2 Operation of the DL-2DH
Operator’s Tour........................................................................ 2-2
Standard ...............................................................................................2-2
DL-2DH Second Cutter Head...............................................................2-2
Option D: Edge Prep.............................................................................2-3
Option G: About Air Nozzles.................................................................2-3
About the Electrical Panels..................................................... 2-4
Description of the Six Light Panel ........................................... 2-5

DL-2DH Door Light Machine
Quick Start Description............................................................ 2-6
Powering Up and Down the DL-2DH...................................... 2-7
To Power Up the DL-2DH.....................................................................2-7
Powering Down the DL-2DH.................................................................2-7
Momentary Stop....................................................................................2-8
To Resume Normal Operation after a Momentary Stop........................2-8
Operator Controls.................................................................... 2-9
Pneumatic Table and Edge Prep Controls..........................................2-10
Edge Prep Controls (Option) ..............................................................2-11
Motor Controls....................................................................................2-12
Head Controls.....................................................................................2-12
DL-2 Setting Up for a Cut ........................................................ 2-14
Door Stop............................................................................................2-14
Face Bore Templates..........................................................................2-14
Edge Detailing Machine......................................................................2-14
Cutter Head Stops ..............................................................................2-15
Cutter Head ........................................................................................2-15
Door Thickness...................................................................................2-15
About Set Collars and Templates ............................................ 2-16
About Y Axis Template Bar(s).............................................................2-16
About Face Bore Templates ...............................................................2-17
Y- Axis Template Bar Set-up...............................................................2-17
Adjusting a Y Template Bar ................................................................2-18
Using Templates...................................................................... 2-21
Positioning the Template.....................................................................2-22
Template Drill Jig ................................................................................2-23
Chapter 3 Maintenance of the DL-2DH
Maintenance Schedule............................................................ 3-2
Daily, Monthly, Six Month Maintenance................................................3-2
Lubrication Schedule............................................................................3-3
Lubrication Requirements........................................................ 3-4
Linear Bearings, Flange Bearing, and Pillow Blocks............................3-4
Gear Motor Lubrication Requirements..................................................3-5
Ball Screws (If Applicable)....................................................................3-5
Description of Air Input System ............................................................3-5
Adjusting the Air Line Lubricator...........................................................3-6
Priming the Air Line Lubricator .............................................................3-6
Changing or Adjusting Bits ...................................................... 3-7

KVAL DL-2DH Operation/Service Manual
Adjusting Drill Unit ................................................................... 3-8
To Adjust Horizontally...........................................................................3-8
Depth of Drilling....................................................................................3-8
Adjusting the Bolt Plate Router.............................................................3-8
Set Up for Wood Rail............................................................................3-8
Chapter 4 Troubleshooting the DL-2DH
DL-2DH Sensors...................................................................... 4-2
How Sensors Work...............................................................................4-2
Troubleshooting Sensors......................................................................4-2
Important Notice about Adjusting Cylinder Speed................... 4-3
Adjusting Cylinder Extend Speed .........................................................4-3
Adjusting Cylinder Retraction Speed....................................................4-3
About a Typical Contactor Control........................................... 4-4
About Contactor Troubleshooting.........................................................4-5
Troubleshooting Electrical Problems ...................................... 4-6
If the Power Stops During Normal Operation........................................4-6
Troubleshooting with the Status Light Panel ........................... 4-8

DL-2DH Door Light Machine

Chapter 1 at a Glance
1-1
KVAL DL-2DH Series Operation/Service Manual
CHAPTER 1 Introduction to the DL-2DH
This chapter provides an overview of the KVAL DL-2DH machine and important safety informa-
tion to follow when operating the machine.
Chapter 1 at a Glance
Chapter 1 at a Glance 1-1
Overview of the DL-2DH 1-2
Options Available 1-3
About this Manual 1-4
Safety Sheet Sign-Off Sheet 1-4
Safety First! 1-5
Safety Sheet Sign-Off Sheet 1-5
Safety Terminology of Labels 1-5
Safety Guidelines 1-5
Lockout-Tagout Guidelines 1-9
Follow the P-R-O-P-E-R lockout rule of thumb. 1-9
Lockout Tagout Procedure 1-10
Pre-Steps Before Lockout Tagout 1-10
Lockout Tagout Power 1-10
Lockout Tagout Air Supply 1-11
Start Maintenance 1-11
Post Maintenance Steps 1-11
Zero-Energy to Start-Up 1-12
Getting Help from KVAL 1-14
On-Line Help 1-14
Product Return Procedure 1-14
How to Download the Service Application 1-16
Download Application 1-16
Safety Sign-Off Sheet 1-19
A Note to the Operator 1-19
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Overview of the DL-2DH
KVAL DL-2DH Series Operation/Service Manual
1-2
Overview of the DL-2DH
KVAL's DL-2DH Door Light Cut-Out Machine produces rectangular, curved, and multi-light cut-
outs in wood or metal doors up to 16 gauge. Face boring is standard with a built-in steel template
adjustable for backsets from 2-3/8” to 2-3/4”.
Steel bars are provided to set the travel in the 'X' (Door length) and 'Y' (Door width) directions for
the cutout. The 'X' axis set up uses a fixed stop for the reference from the top of the door and an
adjustable stop to set the length of the cut. For the 'Y' axis 10 bars with collars are included to set
the width of the cutout are included with the DL-2DH. The stop collars to position the bar for dif-
ferent door widths may be set up set up so the same bar may be used for 3'0", 2-10", and 2'-8"
doors by shifting the collar bar on the holder bracket. The cutout for 2'-6" wide doors will usually
require a separate bar setup to accommodate the narrow doors that are typically used.
Two three-speed Cutter Heads are supported by cross-mounted linear bearing shafts for length
and width travel. Cutter Heads can be used for metal doors and wood doors, cutting down time or
tool change over. A Hardinge B3 1/2" ID collet is used for accurate tool holding.
This design eliminates cut-out templates for rectangular lights since adjustable stops can be
locked directly on the shaft to limit Cutter Head travel. A numeric scale and ratcheting lock han-
dles are provided to make the stops easy to adjust. For curved or multiple light cutouts, plywood
templates slide into a holder 1/4" above the door. The same template may be used for 32” or 36”
doors.
During the cutting operation, the spindle automatically oscillates up and down 3/8” every second
to guard against overheating the same part of the cutting tool, thus ensure even tool wear and lon-
ger tool life.
The standard pass line height of the DL-2DH is 33-1/2”. If the DL-2DH is to be used in a line
with a Handler Door Feeder or any Kval assembly machine option P may added specified to raise
the feed height to 38-1/2"
SPECIFICATIONS
Footprint Size: 7'x 10'
Crated Dimensions: 115"L x 84"W x 60"H
Shipping Weight: 2,000 lbs.

Overview of the DL-2DH
1-3
KVAL DL-2DH Series Operation/Service Manual
Options Available
Option Title Description
Option A: Thumb-Operated Clamping System Locks Cutter Head movement in either the width or length, or in both
directions, like a milling machine. This feature reduces operator
fatigue since he or she does not have to hold the Cutter Head against a
guide. It also makes plugging and set-up easy for peephole drilling.
This option is highly-recommended for all users and is considered a
must for 16-18 gauge hollow metal doors.
Option AE: Pushbutton Operated Door Stop Air operated push button door stop. Includes manual push/pull 4-way
air valve to extend and retract stop.
Option B: Door Cut-Off with Chipout NOTE: Option B not available when second cutting head is installed.
Option C: Heavy-Duty Edge Drill For driving in bolt holes in wood or residential steel-edge doors.
Option D: Edge Detailing for Wood Edge
Doors Includes edge drill and 1” x 2-1/4” faceplate. Provides a semi-auto- matic operation enabling the machine operator to select the drill or
router with a toggle valve and then activate the drill with a pushbutton
or cycle the router with joy-stick, all without moving the door.
Option DC: Dust Collection System for DL-
2DH C330-1 Dust Collection fan equipped with silencer, cartridge filter (1),
start/stop switch mounted on the fan.
Also includes all air pipe, pipe fittings, clamps, flexible hose, and
bracket bolted to the DL-2DH frame to support the dust collection
piping. 13 foot ceiling height required for dust collection piping. Cus-
tomer is responsible suspending the the overhead dust collection pipe
to the building.
Note: Separate three phase electric supply required for 3HP fan motor.
Note: Replacement plastic bags may be purchased in full cartons. 50
bags per carton for $140.00 plus shipping costs. Order from KVAL
parts sales.
Option F: Extra Doorstop for Deadbolt or
Additional Face Bores
Option F1: Extra Door Stop for Deadbolt on
8’0” Doors
Option G: Automatic Door Blow-Off System Cleans chips and foam from door as it off-feeds.
Option H1: Side Light Fixture Allows machining of side lights ranging from a minimum of 11-3/4"
to a maximum of 17"wide and will accommodate door lengths from
72" to 96".
Option I: 5” Duct Dust Collection Hood For the Cutter Head.
Option J: Reverse Feed Direction Doors normally feed from operators right to left.
Option L: Keyless Deadbolt Allows routing of round hole halfway through door. Note: Option K -
Single Skin required with this option.

Overview of the DL-2DH
KVAL DL-2DH Series Operation/Service Manual
1-4
About this Manual
This manual contains operation information and service and maintenance information.
It includes identification of machine assemblies, power-up and power-down steps, and informa-
tion about using the user interface.
The Troubleshooting and Maintenance sections are directed toward qualified service technicians.
TABLE 1.
Title Part Number
DL-2DH Operation and Service Manual 126_OPSRV_DL2_V1
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-19.
Option K: Single Skin Enables operator to cut one skin at a time; used primarily with 16 and
18 gauge doors.
Option N: Anti-Static Bar Air Blow-Off.
Option O: 8’0" Door Capability Includes door stop and accommodates maximum door length of 95”.
Option P: Leg Extensions Four leg extensions to elevate pass line height to 38-1/2”.
Option R: Drill Template Shelf for Remodel
Doors Guide hole for template index pins offset 1/2" for remodel doors that are 1" narrower than new construction doors.
Option U: Garage Door Light Cut-Out Fixture Includes hold-up wheels and index modifications.
Option V: r High-Frequency Route 11 HP High-Frequency 3-phase motor replaces belt driven spindle.
Option: Tooling and Lubricant Package Please review with your KVAL consultant to determine your needs.
Option: Spare Parts Package Please review with your KVAL consultant to determine your needs.
Option Title Description

Safety First!
1-5
KVAL DL-2DH Series Operation/Service Manual
Safety First!
This machine is a powerful electro-mechanical motion control
system. You should test your motion system for safety under
all potential conditions. Failure to do so can result in dam-
age to equipment and/or serious injury to personnel.
Safety Sheet Sign-Off Sheet
At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-
teria to understand before operating the machine. It is highly recommended that personnel operat-
ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be
signed and kept for records. See “Safety Sign-Off Sheet” on page 1-19.
Safety Terminology of Labels
In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-
vide safety information to operators. Safety labels should be clearly visible to the operator and
must be replaced if missing, damaged, or illegible.
There are three types of warning labels or decals:
•DANGER means if the danger is not avoided, it will cause death or serious injury. 
•WARNING means if the warning is not heeded, it can cause death or serious
injury. 
•CAUTION means if the precaution is not taken, it may cause minor or moderate
injury.
Safety Guidelines
In addition to the caution and warning labels affixed to this machine, follow the guidelines below
to help ensure the safety of equipment and personnel.
Ensure that all employees who operate this machine
are aware of and adhere to all safety precautions
posted on the machine and are trained to operate this
machine in a safe manner.
Training

Never operate the machine without proper eye and
ear protection.
Protective Gear
• Never reach hands beyond safety cage. Servo
motors can unexpectedly move quickly.
• Never clear screws or hinges out of the machine
while it is running.
• Never reach into the router area to retrieve a
hinge. The router may still be running down
after shut down.
• Never perform any maintenance unless machine
is at zero state.
• Never clean the machine while it is running.
• Never walk away from the machine while it is
running.
When the Machine is ON
The compressed air system connected to this
machine should have a three-way air valve
for shut-off and pressure relief.
All cylinders on machine are under high
pressure and can be very dangerous when
activated. Before performing any mainte-
nance or repairs on this machine turn off the
main air disconnect. Lockout and tagout
this connection.
See “Lockout Tagout Procedure” on
page 1-10.
Compressed Air
Safety First!
KVAL DL-2DH Series Operation/Service Manual
1-6

Electrical circuitry on this
machine is protected by an
approved lockable disconnect
circuit. In addition to this equip-
ment, you must install an
approved disconnect for the
electrical power supplying this
machine.
When opening the cabinet you must first turn off the
disconnect switch. When the cabinet door is open there
is still power on the top side of the disconnect switch.
Some machines are powered by more than one supply
located at different locations. Before performing any repairs or mainte-
nance, lockout and tagout must be installed at all locations
All maintenance and repairs to electrical circuitry should only be per-
formed by a qualified electrician.
Still has power
in OFF position
Electrical
Prior to performing any maintenance, repairs,
cleaning or when clearing jammed debris, you
must disconnect, tag out, or lock out the electrical
and air pressure systems. This should be done in
accordance with applicable state and/or federal
code requirements.
Before Conducting Maintenance
Laser Warnings
On some machines, laser indicators are used to set boundaries. Follow the
manufacturers safety precautions.
Safety First!
1-7
KVAL DL-2DH Series Operation/Service Manual

KVAL advises that you request an on-site state
safety review of your installation of this
machine. This is to ensure conformance to any
additional specific safety and health regula-
tions which apply in your geographic area.
Compliance with Codes and Regulations
Other Hazard Control Action
Report a Hazard
Before You Report an Accident
If you believe any part or operation of this machine is in
violation of any health or safety regulation, STOP pro-
duction. It is your responsibility to immediately protect
your employees against any such hazard.
Additional detailed safety guidelines are included in the
operating instructions of this manual. KVAL will be
pleased to review with you any questions you may have
regarding the safe operation of this machine
Follow Your Company’s Safety Procedures
In addition to these safety guidelines. Your company
should have on-site and machine specific safety proce-
dures to follow.
Safety First!
KVAL DL-2DH Series Operation/Service Manual
1-8

Lockout-Tagout Guidelines
1-9
KVAL DL-2DH Series Operation/Service Manual
Lockout-Tagout Guidelines
• Place a tag on all padlocks. On the tag, each
operator must put their own name and date.
(These locks are only to be removed by the
person who signs the tag)
• If more than one person is working on the
machine, each additional person places a lock
and tag on each disconnect.
• Only each operator may remove their own
lock and tag.
Important: When many people are all working
on the same machine you will need a multiple
lockout device, such as the one shown here.
Follow the P-R-O-P-E-R lockout rule of thumb.
P...... Process shutdown
R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)
O...... OFF! Shut off all power sources and isolating devices
P...... Place lock and tag
E...... ENERGY: Release stored energy to a zero-energy state
R ...... Recheck controls and test to ensure they are in the “OFF” state

Lockout Tagout Procedure
KVAL DL-2DH Series Operation/Service Manual
1-10
Lockout Tagout Procedure
This policy is required by OSHA regulation 1910.147 and Cal OSHA’S
SB198 ruling of July 1991.
Use the following lockout procedure to secure this machine while it is
powered down. During a lockout, you disconnect all power and shut
off the air supply. Be sure to use the tagout guidelines noted below.
Pre-Steps Before Lockout Tagout
1. Evaluate the equipment to fully understand all energy sources (multiple electrical
supplies, air supply and pressure, spring tension, weight shifts, etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration of the
shutdown.
3. Obtain locks, keys, and tags from your employer’s lockout center.
Lockout Tagout Power
4. Turn off machine. See Chapter 2 for power down and power up procedures.
5. Turn the disconnect switches on ALL electrical and frequency panels to the OFF
position. Then push the red tab to pop it out. Place a padlock through the hole.
Place your tag on the padlock, as per the tagout guidelines below. (see illustration
below).
Power
Note: When multiple people are working on the machine, each person needs to
have a lock on the handle in the extra holes provided.
Insert Lock into hole.
Turn Switch to the
OFF position Lock and Tag out

Lockout Tagout Procedure
1-11
KVAL DL-2DH Series Operation/Service Manual
Lockout Tagout Air Supply
6. Turn all air valves to the OFF position and place a pad-
lock through the hole (see illustration below).
NOTE: Place your tag on the padlock, as per the
tagout guidelines.
Start Maintenance
7. Once the locks and tags are in place and all personnel are clear, attempt to operate
the machine to ensure equipment will not operate.
8. Maintenance or repairs may started.
Post Maintenance Steps
9. After maintenance is completed, the person performing the work must ensure all
tools, spare parts, test equipment, etc., are completely removed and that all guards
and safety devices are installed.
10. Before removing the locks and tags, the person who attached them shall inspect the
equipment to ensure that the machine will not be put in an unsafe condition when
re-energized.
11. The lock and tag can now be removed (only by the person(s) who placed them),
and the machine can be re-energized.
12. The tags must be destroyed and the locks and keys returned to the lockout center.

Zero-Energy to Start-Up
KVAL DL-2DH Series Operation/Service Manual
1-12
Zero-Energy to Start-Up
Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of
safety.
Start-up Guidelines
The following guidelines below should be followed to start the equipment.
Inspect
The equipment must be inspected for proper adjustment before starting equipment.
Clean Up
All materials and debris must be cleaned up. Any combustible materials or old parts
used during repairs must be cleaned up and/or properly disposed of.
Replace Guards
Replace all equipment guards. If part of equipment cannot be properly adjusted after
start-up with guard on, contact the KVAL Service team. See “Getting Help from
KVAL” on page 1-14.
Check Controls
Confirm that all switches are in the “OFF” position. Please be advised that some com-
ponents of the machine may start automatically when energy is restored.
Remove Locks
Each operator must remove his or her own lock and tag. This will ensure that all oper-
ators are in a safe place when the equipment is started.
Perform Visual Checks
If the equipment is too large to see all around it, station personnel around the area and
sound the personnel alarm before starting the equipment. If your operation is more
complex, your company’s comprehensive safety procedure may involve additional
steps. You will need to ask your supervisor about these procedures. The company’s
lockout procedure should be posted at each machine. On larger or long-term mainte-
nance or installation projects, the company’s procedures must be explained to all new
operators and a copy of the company’s procedures should be posted on-site for the
duration of the work.
The Company’s procedures should also include provisions for safely handling shift
changes and changes in operators or new operators.Comprehensive lockout/tagout
may use a gang box or other system to ensure that locks are secure and not removed
without authorization.