Kval Commander 3 User manual

Innovation, Quality & Honesty
Commander III Door System
With KvalCAM®
Commander III Service Manual
Service Manual
Published: December 21, 2022

KVAL Commander III 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 Technical Support at [phone] or fax [phone].
Manual Name: Commander III Door System Service Manual
Manual Revision: 202-MV100.2, 202-MV101.0, 202-MV101.1
Commander III is a trademark of Kval Incorporated.
KvalCAM® is a registered trademark of Kval Incorporated.
Copyright 2022 Kval Incorporated. All rights reserved.
Beckhoff®, TwinCAT®, and EtherCat® are registered trademarks and are licensed by Beckhoff
Automation GmbH
All other products are trademarks or registered trademarks of their respective holders, all rights
reserved. Reference to these products is not intended to imply affiliation with or sponsorship of
Kval Incorporated.
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Mailing address:
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Petaluma, CA 94952
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Contact us for all parts related needs, from orders to inquiries. Call, email, contact us on our web-
site at the “Contact Us” page.
email: pa[email protected]

KVAL Commander III Service Manual
KVAL Commander III Service Manual
Technical Support
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Us” page.
Mon-Fri:4:00 AM - 4:00 PM PST
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KVAL Commander III Service Manual
NOTICE OF OWNERSHIP OF KVALCAM SOFTWARE AND LIMITED LICENSE TO
USE
READ THIS NOTICE CAREFULLY BEFORE USING THE KVALCAM SOFTWARE WHICH OPERATES
KVAL MACHINERY. THIS DOCUMENT CONSTITUTES NOTICE TO YOU THAT YOU HAVE A LIMITED
LICENSE TO USE THE KVALCAM SOFTWARE ON THE TERMS AND CONDITIONS APPEARING BELOW.
BY USING THE KVALCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED
LICENSE. IF YOU DO NOT AGREE TO ALL OF THE TERMS OF THIS LICENSE, THEN DO NOT USE THE
KVALCAM SOFTWARE.
KVAL, Inc., is the owner of all rights in respect of the software and documentation (referred to as “Licensor”). You
are the purchaser of KVAL Machinery operated by the KVALCAM Software are the “Licensee”.
The computer program(s) and related documentation and materials (herein collectively referred to as “the KvalCAM
Software” and further defined herein) which are used in the operation of the KVAL Machinery are licensed, not sold,
to you for use only upon the limited terms of this license, and Licensor reserves any rights not expressly granted to
you. Licensor retains all ownership of the KvalCAM Software.
Title, ownership rights, and intellectual property rights in the KvalCAM Software shall remain with KVAL, Inc. The
KV
ALCAM Software is protected by copyright laws and treaties. Title and related rights in the content generated
through the KVALCAM Software are also the property of the Licensor and are protected by applicable law.
1. Definitions.
a.“KVALCAM Software” means the KVALCAM computer application installed in the KVAL
Machinery and written documentation and materials provided to you, as well as any revisions or
updates of such computer application and documentation.
b.“Install” means storing of the KVALCAM Software in the computer component of the KVAL
Machinery.
c.“Use” means executing the KVALCAM Software for purpose of operating the KVAL
Machinery and use of the documentation for properly operating KVALCAM Software.
2. Grant of License.
a.Licensor hereby grants Licensee a non-exclusive, non-transferable license to Use the KVAL-
CAM Software upon payment of all amounts due for the purchase of the related KVAL Machin-
ery.
b.Licensee will make no copies of the KVALCAM Software or alter the KVALCAM Software
in any way. Title to the KVALCAM Software will remain vested in Licensor, and nothing in this
License will give or convey any right, title or interest therein to Licensee except as a licensee.
c.Licensee agrees that it will use the KVALCAM Software or related documentation directly or
indirectly for the benefit of Licensee, and only pursuant to the scope of the grant of the License
set forth herein.
d.Licensee will not decode, alter, decompile, reverse engineer, perform reverse analysis on or
disassemble the KVALCAM Software.
e.This License will terminate automatically if Licensee fails to comply with the limitations
described above.

Table of Contents
Commander III
Chapter 1 Introduction to the Commander III
Chapter 1 at a Glance.............................................................. 1-1
Overview of the Commander III System .................................. 1-2
KvalCAM and the Commander III.........................................................1-2
Standard Features................................................................................1-2
Additional Features...............................................................................1-3
Table of Options...................................................................................1-4
About this Manual.................................................................................1-5
Operation Manual .................................................................................1-5
Service Manual.....................................................................................1-5
KvalCAM Reference Manual ................................................................1-6
Safety First!.............................................................................. 1-7
Safety Sheet Sign-Off Sheet.................................................................1-7
Safety Terminology of Labels................................................................1-7
Safety Guidelines..................................................................................1-7
Lockout-Tagout Guidelines ...................................................... 1-11
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-11
Lockout Tagout Procedure....................................................... 1-12
Pre-Steps Before Lockout Tagout.......................................................1-12
Lockout Tagout Power ........................................................................1-12
Lockout Tagout Air Supply ..................................................................1-13
Start Maintenance...............................................................................1-13
Post Maintenance Steps.....................................................................1-13
Zero-Energy to Start-Up .......................................................... 1-14
Zero-Energy State to Start-Up to Operating State..............................1-14
Getting Help from Kval............................................................. 1-16
Kval Return and Warranty Policy............................................. 1-17
Send the Item .....................................................................................1-17
Acceptance of Return .........................................................................1-17
Refund Turnaround Time....................................................................1-17
Kval Errors..........................................................................................1-17
Customer Errors .................................................................................1-18
Shipper Errors.....................................................................................1-18
Warranty Replacement Parts..............................................................1-18
Safety Sign-Off Sheet .............................................................. 1-20
A Note to the Operator:.......................................................................1-20

Commander III
Table of Contents
Chapter 2 System IT Administration
System IT Administration ......................................................... 2-2
About the Commander III Computer.....................................................2-2
Connections on the PLC.......................................................................2-2
About Remote Connection to KVAL Service............................ 2-3
Network Diagram..................................................................................2-3
Chapter 3 Maintenance of the Commander III
Maintenance Schedule ............................................................ 3-2
300 Cycle Maintenance Steps ................................................. 3-4
Clean, Clean, Clean!.............................................................................3-4
600 Cycle Maintenance Steps ................................................. 3-5
Check Air Gauges and Inspect Water Traps.........................................3-5
Inspect Tooling......................................................................................3-5
Empty Dust Collection Units .................................................................3-6
3,000 Cycle Maintenance Steps .............................................. 3-7
Inspect Feed Belts (If Applicable) .........................................................3-7
Inspect all Photo Eyes ..........................................................................3-7
Inspect Limit Switches ..........................................................................3-7
Inspect Airlines......................................................................................3-8
Refill Lubricators (If Applicable) ............................................................3-8
Grease Ball Screw Bearings.................................................................3-9
Clean Bearing Shafts............................................................................3-9
12,000 Cycle Maintenance Steps............................................ 3-10
Inspect Chains for Proper Tension......................................................3-10
Inspect Air Cylinders ...........................................................................3-10
Inspect Hydraulic Lines.......................................................................3-10
Inspect Ball Rail Shafts and Ball Screws............................................3-11
Clean and Lubricate Slides, Cylinder Rods and Bearing Shafts.........3-11
72,000 Cycle Maintenance Steps............................................ 3-12
Inspect Nuts and Bolts........................................................................3-12
Check Door Feeding Transition ..........................................................3-12
Electrical .............................................................................................3-12
Computer Backup...............................................................................3-13
Wash Filter and Lubricator Bowls .......................................................3-13
Maintenance NO-GOES .......................................................... 3-14
Lubrication Schedule ............................................................... 3-15
Typical Lucubration Kit........................................................................3-15

Table of Contents
Commander III
Lubrication Requirements........................................................ 3-16
Pillow Block Bearing Housings ...........................................................3-16
Flange Bearing Housings ...................................................................3-17
Ball Rail Bearing .................................................................................3-17
About Taper Bearings .........................................................................3-18
Tapered Bearing Housings .................................................................3-18
Ball Screw Nut ....................................................................................3-19
Ball Screw Drive Assembly .................................................................3-19
Pulley and Idler Shafts........................................................................3-20
About Grease Locations for the Machine ................................ 3-21
Servo Motor Drive Assembly Grease Locations ...................... 3-22
Frame Servo Grease Locations..........................................................3-23
Recommended Tools ..........................................................................3-23
Front Section Servo Assemblies.........................................................3-24
Recommended Tools ..........................................................................3-24
Cutter Head Grease Locations ............................................... 3-25
Recommended Tools ..........................................................................3-25
Cutting Head Base Grease Locations ................................................3-25
Cutting Head Tools Grease Locations ................................................3-26
Recommended Tools ..........................................................................3-26
Back Section Grease Points .................................................... 3-27
Recommended Tools ..........................................................................3-27
Grease Location on the Frame (Feed System) ....................... 3-28
Recommended Tools ..........................................................................3-28
Air Input with Lubrication ........................................................ 3-29
Adjusting the Air Line Lubricator ........................................................3-29
Priming the Air Line Lubricator............................................................3-30
Air Line Without Lubricator .................................................................3-30
Identifying Cutting Tools........................................................... 3-31
Tool Information for the Hinge Carriage..............................................3-31
Tool Information for the Lock Carriage................................................3-32
Replacing Bits in the Front Section ......................................... 3-33
How to Access to Bit Assemblies........................................................3-34
Remove and Replace the Router or Pre-Drill Bits ..............................3-34
Remove and Replace the Chisels ......................................................3-36
Replacing Tooling in the Back Section..................................... 3-37
Changing the Bore Drill.......................................................................3-37
Changing the Bolt Drill........................................................................3-38
Changing the Face Plate Drill.............................................................3-38

Commander III
Table of Contents
Chipout Block Replacement .................................................... 3-39
Tools ...................................................................................................3-39
How to Replace the Back Section Chipout Block ...............................3-39
How to Burn in the Chipout.................................................................3-40
Option W: Replacing Function Drill Assembly ......................... 3-41
Collet Torque Values................................................................ 3-42
Addition Collet Torque Values.............................................................3-43
Chapter 4 Troubleshooting the Commander III
Get Live Technical Help ........................................................................4-1
About Motion Control ............................................................... 4-2
Sequencing:..........................................................................................4-2
Point to Point: .......................................................................................4-2
Incremental:..........................................................................................4-2
Basic Control Circuit .............................................................................4-3
About a Typical Contactor Control ........................................... 4-4
About Contactor Troubleshooting .........................................................4-5
About Typical VFD Motor Drive Control................................... 4-6
About the VFD ......................................................................................4-7
About VFD Troubleshooting..................................................................4-8
Error Checking on the Variable Frequency Drives................................4-8
Using the Reset Buttons.......................................................................4-8
About a Typical Pneumatic Circuit ........................................... 4-9
Typical Pneumatic Assembly ..............................................................4-10
About the Coil (Solenoid)....................................................................4-10
About Cylinder Operation ...................................................................4-11
How the Pneumatic System Works ....................................................4-11
Extend Process...................................................................................4-11
Retract Process ..................................................................................4-12
Important Notice about Adjusting Cylinder Speed ..............................4-14
Adjusting Cylinder Extend Speed .......................................................4-14
Adjusting Cylinder Retraction Speed .................................................4-14
About Switches and Sensors................................................... 4-15
Using Sensors to Trouble Shoot .........................................................4-16
Troubleshooting Electrical Problems ....................................... 4-17
If the Power Stops During Normal Operation .....................................4-17
Description of the Light Tower ................................................ 4-19
Network System Overview....................................................... 4-20

Table of Contents
Commander III
Connections to Servo Drives ..............................................................4-20
Connections to VFD’s (High Freq Panel)............................................4-20