Kval Commander III User manual

Innovation, Quality & Honesty
Commander III Operation Manual
With KvalCAM
Commander III Door System
Operation Manual
Published: October 6, 2020

KVAL Commander III Operation 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: DOC-202_3-OPKvalCAM
The Commander-III is a trademark of Kval Incorporated.
Copyright 2020 Kval Incorporated. All rights reserved.
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by Beckhoff Automation GmbH
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All other products are trademarks or registered trademarks of their respective holders,
all rights reserved. Reference to these products is not intended to imply affiliation with
or sponsorship of Kval Incorporated.
Contacting KVAL
Customer Service: For further information about this manual or other Kval Incorpo-
rated products, contact the Customer Support Department
• Mailing address:
Customer Support Department
Kval Incorporated
825 Petaluma Boulevard South
Petaluma, CA 94952
• Phone and Fax:
In the U.S and Canada, call [phone] or fax [phone]
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• Business hours:
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(Other sales related inquiries: http://www.kvalinc.com)
• Email: [email protected]

KVAL Commander III Operation Manual
KVAL Commander III Operation Manual
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and your business more successful, we'd like to gain your perspective about your user
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KVAL Commander III Operation 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
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BY USING THE KvalCAM SOFTWARE YOU ARE CONSENTING TO BE BOUND BY THIS LIMITED
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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”.
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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 Machin-
ery 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-
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e.This License will terminate automatically if Licensee fails to comply with the limitations
described above.

Table of Contents
KVAL Commander III Manual
Chapter 1 Introduction to the Commander III
Chapter 1 at a Glance.............................................................. 1-1
Overview of the Commander III System.................................. 1-2
Table of Options...................................................................................1-3
About this Manual.................................................................................1-5
Safety Sheet Sign-Off Sheet.................................................................1-5
Safety First!.............................................................................. 1-6
Safety Sheet Sign-Off Sheet.................................................................1-6
Safety Terminology of Labels................................................................1-6
Safety Guidelines..................................................................................1-6
Lockout Tagout Procedure..................................................................1-10
Follow the P-R-O-P-E-R lockout rule of thumb...................................1-12
Zero-Energy to Start-Up........................................................... 1-13
Zero-Energy State to Start-Up to Operating State ..............................1-13
Getting Help from KVAL........................................................... 1-15
On-Line Help.......................................................................................1-16
Product Return Procedure..................................................................1-16
How to Download the Service Application............................... 1-17
Download Application.........................................................................1-17
Safety Sign-Off Sheet.............................................................. 1-20
A Note to the Operator:.......................................................................1-20
Chapter 2 About KvalCAM
About KvalCAM ....................................................................... 2-2
Summary of the KvalCAM Interface ........................................ 2-3
Machine Line ........................................................................................2-3
Libraries................................................................................................2-3
Machine Control....................................................................................2-4
About the Libraries................................................................... 2-5
Distinguish Between the Library Types.................................................2-5
Around the Door Job Library Screen....................................................2-6
Around the Door Data Library Screen ..................................................2-6
Around the Feature Group Library Screen ...........................................2-7
Controls at the Library Screen................................................. 2-8
Using the Door File Table .....................................................................2-9
Using the Display Deleted Check Box (Recover a Door File)...............2-9
Using the File Control Buttons............................................................2-10
Using the Create Button .....................................................................2-10

KVAL Commander III Manual
Table of Contents
Using the Edit/View Button.................................................................2-10
Using the Clone Button.......................................................................2-10
Using the Delete/Restore Button........................................................2-11
Using the Diff Button...........................................................................2-12
About the Database Icon....................................................................2-13
About Revisions....................................................................... 2-14
Principle and Diff.................................................................................2-14
Revisions at the Door Job Library.......................................................2-14
Revisions at the Door Data Library.....................................................2-15
Revisions at the Door Feature Group Library.....................................2-15
About Door Job Creation......................................................... 2-17
About the Job Name Menu.................................................................2-18
About the Door Data Menu.................................................................2-18
About the Feature Tree Menu.............................................................2-19
Breakdown of a Feature Group and Features....................................2-19
About the Feature Tree Menu.............................................................2-20
About the Selected Feature Details Menu..........................................2-21
About the Selected Feature Details Menu (Child Level).....................2-22
About the Control Buttons...................................................................2-23
About the Job Preview Screen (2D and 3D).......................................2-24
2 D Screen..........................................................................................2-24
3 D Screen..........................................................................................2-25
About the Machine Line Screen............................................... 2-26
Machine Line Screen..........................................................................2-26
About Backing up Data and Checking the Revision Status..... 2-30
Job Preview Examples ............................................................ 2-31
Door Face (Lock Preview)..................................................................2-31
Door Edge (Lock Preview)..................................................................2-32
Door Edge (Hinge Preview)................................................................2-33
About Validation....................................................................... 2-34
About the Validation Screen ...............................................................2-35
Outline ................................................................................................2-36
About the LiteCutout Feature Detail (DL-NCD Only)............... 2-37
Process...............................................................................................2-37
About the LiteCutout Screen...............................................................2-41
About the Work Area Coordinates......................................................2-42
Sample Oval Cut.................................................................................2-43
Common Terms ....................................................................... 2-45
Door Job.............................................................................................2-45
Door Data ...........................................................................................2-45

Table of Contents
KVAL Commander III Manual
Feature Group ....................................................................................2-46
Feature ...............................................................................................2-47
Revision..............................................................................................2-47
Ad Hoc................................................................................................2-47
Variant.................................................................................................2-48
Diff ......................................................................................................2-49
Axis.....................................................................................................2-49
Validation............................................................................................2-50
Validation Report ................................................................................2-50
Chapter 3 Operation of the Commander III
About the Commander III Process........................................... 3-2
Summary of Machining a Door................................................ 3-3
Start the Process ..................................................................................3-3
Load Door Job from KvalCAM..............................................................3-3
Load Door.............................................................................................3-4
Set-Up Front Section and Machine the Door........................................3-5
Powering Operations for the Commander III........................... 3-6
How to Power Up the Commander III...................................................3-6
Home the Commander III .................................................................... 3-7
How to Power Down the Commander III ..............................................3-7
Emergency Shutdown and Recovery ...................................................3-8
About Machine Status Feedback............................................. 3-9
About the Commander III interface Screens............................ 3-10
Screen Tabs........................................................................................3-10
About the Main Control Screen................................................ 3-11
Machine Controls Section........................................................ 3-12
About the Main Control Section..........................................................3-13
About Sequence Control Section........................................................3-14
About Width Adjust.............................................................................3-14
About Carriage Control.......................................................................3-15
About Ball Catch.................................................................................3-16
About Speed Control ..........................................................................3-16
Machine Feedback and Machine Controls .............................. 3-17
About the Top Feedback Bar..............................................................3-18
About Hinge Tasks Control.................................................................3-18
Hinge Block Descriptives....................................................................3-19
About the Background Colors.............................................................3-19
Shelf Pin Configure and Jamb Stop Section.......................................3-20

KVAL Commander III Manual
Table of Contents
About the Manual Servo Control Screen................................. 3-22
Manual Servo Control.........................................................................3-23
Lock Head Movement.........................................................................3-23
Outfeed Stop.......................................................................................3-23
Hinge Carriage....................................................................................3-24
Lock Head Movement.........................................................................3-24
About the Tool Config Tabs...................................................... 3-25
Unlock the Tool Slot Configuration......................................................3-26
About Using Tool Configuration..........................................................3-26
Enable or Disable Tool........................................................................3-27
About Hinge Tool Configuration..........................................................3-27
About Lock Tool Configuration............................................................3-28
About the Ball Catch Configuration.....................................................3-31
About the Tool Path Preview Test Screen................................ 3-32
About the Status Screen.......................................................... 3-33
About the Log Screen.............................................................. 3-34
Description of the Six Light Panel ........................................... 3-35
Chapter 4 Calibration of Commander III
Chapter 4 at a Glance.............................................................. 4-1
About Calibration..................................................................... 4-2
About the Calibration Menus and the Calibration Reference Cut.........4-2
Before you Calibrate.............................................................................4-2
Flow Chart of Calibration .....................................................................4-3
About the Calibration Tabs....................................................... 4-4
Access to the Calibration Adjustments.................................................4-4
Unlock the Calibration (Option).............................................................4-5
How to Enter Calibration Data................................................. 4-6
About The Calibration Box....................................................................4-6
About Restore Points............................................................................4-7
Enter a Positive or Negative Number? .................................................4-7
Axis Direction for Front Section............................................................4-7
Axis Direction for Back Section.............................................................4-8
Suggested Order of Calibration............................................... 4-9
Start with a Right Hand Door................................................................4-9
Machine a Left Hand Door....................................................................4-9
About the Calibration Screens................................................. 4-10
Summary of Calibrations ....................................................................4-10

Table of Contents
KVAL Commander III Manual
Opt FC Added Calibrations.................................................................4-11
Summary of Calibrations for Opt FC...................................................4-11
Hinge Head (Over All).........................................................................4-12
Hinge Tools.........................................................................................4-13
Chisels Calibration..............................................................................4-14
Hinge Carriage Location.....................................................................4-15
Lock Head...........................................................................................4-16
Opt FC: Commander III Faceplate and Chisel Calibrations................4-18
Lock Head General.............................................................................4-18
Axis Calibration Direction....................................................................4-19
Plate Router Calibration (Back Section).............................................4-19
Chisel Calibration (Back Section).......................................................4-20
Door Stops..........................................................................................4-20
Fast and Slow Lock Plate Timing .......................................................4-21
About Lock Plate Timing Calibration...................................................4-22
Feed System Timing...........................................................................4-22
H-Block Display and Jamb Adjustments.............................................4-23
Door and Jamb Depth Adjustment Mapping.......................................4-24
Special Options (Calibrations) ................................................. 4-26
Thickness Feeler Option.....................................................................4-26
Thickness Feeler Calibration..............................................................4-26
Process to Calibrate Thickness Feelers.............................................4-26
Chapter 5 Tour of the Commander III
Operator’s Tour........................................................................ 5-2
Top View...............................................................................................5-2
In-Feed Section: ...................................................................................5-3
Front Section ........................................................................................5-4
About the Operators Station ................................................................5-5
Hinge Carriage......................................................................................5-6
Back Section:........................................................................................5-7
Option FC: CNC Faceplate and Chisels...............................................5-8
Out-Feed:..............................................................................................5-9
About the Electrical Panels...................................................... 5-10
The Main Electrical Panel:..................................................................5-10
The High Frequency Panel.................................................................5-11
Description of the Six Light Panel ........................................... 5-12
About Switches and Sensors................................................... 5-13
Options .................................................................................... 5-15
Option ND: Narrow Door Fence..........................................................5-15

KVAL Commander III Manual
Table of Contents
Option W: Lever Lock Drill (Function Drill)..........................................5-16
Option: Thickness Feelers..................................................................5-17
Option BC: Ball Catch.........................................................................5-18
Option SJ: Split Jamb .........................................................................5-19

1-1
CHAPTER 1 Introduction to the Commander III
This chapter provides an overview of the KVAL Commander III System and important safety
information to follow when operating the machine.
Chapter 1 at a Glance
The following information is available in this chapter
Section Name Summary Page
Overview of the
Commander III
System
This section provides an overview of the Commander
III. It includes a general description and a table of
available options
page 1-2
Safety First! IMPORTANT safety information is described in this
section page 1-6
Zero-Energy to Start-
Up
Procedure to power up your machine for the first time. page 1-13
Getting Help from
KVAL
This section describes the method to contact the KVAL
service center for help. The section includes how to
get information from the specification plate tor provide
to KVAL, service center hours, and return procedures
page 1-15
How to Download the
Service Application
Procedure to download an interactive application to
allow Service Technicians to control your machine and
help troubleshoot.
page 1-17
Safety Sign-Off Sheet A record to track operators that are trained on the
machine. page 1-20

Overview of the Commander III System
KVAL Commander III Operation Manual
1-2
Overview of the Commander III System
The Commander III incorporates CNC movements on six axes and a Beckhoff touch screen to
automate setup for up to 12 different door specifications. Custom specifications can also be
entered directly at the touch screen for special doors.
An optional package for architectural door processing is also available including a PC interface
and Kval software that allows unlimited predefined set-ups for doors up to 2-1/4” thick and bar-
code scanner for program selection.
Standard features include:
Hinge Head – dual spindle routers with counter rotation for clean entry and exit at hinge corners
(eliminates traditional chip-outs), programmable point to point drill for screw pilot holes, and cor-
ner square chisels for door and jamb. Full X, Y and Z axis programming is combined with preci-
sion ball screws and servo motors. Auto tilt between a three degree door edge and jamb clamped
in the square H blocks so both can be processed simultaneously, as well as auto detect for jamb
only and door only processing without wasted motions.
Hinge Centers – no collar bars - automatic adjustment with precision encoder system combined
with a servo motor drive and position lock. The traditional chain and torque limiter are retained so
an operator can fasten the first hinge after the hinge head shifts to the second hinge location. A
couple of manual adjustments for H blocks and jamb clamps are still necessary, but a pointer and
setup mode reduce this to under two minutes and eliminates errors.
Lock Locations – fully automatic positioning for lock locations from the door top, and up to three
locks can processed on one door. Program selection for lock hole backsets of 2-3/8” or 2-3/4” and
either 1” or 1-1/8” face plate width at zero or three degrees (two auto selections). Up to 5” backset
and up to 1-1/4” x 12” face plates can be manually adjusted. Option FC adds corner squaring and
full CNC control of face plate routing.
Door Reference Stops – fully automatic positioning of off-feed door stop to match door length and
hinge off-set with a ball screw and servo motor. The in-feed stop is fixed and is the zero reference
for all other settings.
Additional features include:
• Efficient hinge and lock dust take-off connections
• Auto width adjust to match incoming door
• Door feed system with parallel non-marking belts and heavy duty AC drive for
smooth speed transitions at door reference stops.
• 5HP lock bore, and 3 HP latch bore with precision Accuflex collets and nuts
• Auto door clamp
• Air blow-off to clean the face as the door off-feeds.
• Door hand indicator light to speed processing in a companion 700C door framer.
Operators Interface:
The operator interface for the Commander III is simple and requires very minimal training to cre-
ate door specifications. Dimensions are entered at the amply sized 19” Beckhoff touch screen for
hinge layout from the door top, hinge reveal, hinge size, ¼”radius, 5/8”radis or square corners,

Overview of the Commander III System
1-3
KVAL Commander III Operation Manual
hinge bevel (0 or 3), lock locations, lock backset (2-3/8” or 2-3/4”) and door length. Multiple pat-
terns for screw pilot hole can be selected from a drop down list. Each specification can be
assigned to one of the twelve preset buttons, or run as a special. Left or right hand processing is
via selector switch. A key switch is provided to lock out access to specification changes.
About the Software:
The backbone of the Commander III is a Beckhoff control system with integrated components
including all Beckhoff servo motor and drives. This makes remote support and program updates
easier than ever before. A connection to the internet is required for remote support from Kval,
which can remain physically disconnected except when needed. Software is pre-installed to mon-
itor all machine functions from our offices in Petaluma when required.
Table of Options
Option Title Description
Option
AH Reverse Feeds Facing the hinge routing head, the normal direction is left to right. This option reverses the feed direction to
feed from right to left.
Option
AR Architectural Door Package Adds a barcode scanner and processing for architec- tural doors up 2-1/4” thick., which integrates with the
machine’s industrial PC and CNC positioning motors
to completely automate hinge, pattern processing
and lock locations. Door files can be created with the
software which can reference barcode labels, or be
selected from an on screen list for nearly instant
machine set-up. The door files hare identical to those
used in the Kval Face, Edge and DLNC series
machines so one file can be created to be used in
multiple operations. Anti-Static air blow bar to clean
door face is also included in this package.
Option
FC CNC Lock Face Plate with Chis- els Only available in combination with option AR. Adds CNC control of face plate routing and corner squaring
of face plates. Includes programming and three addi-
tional servo motors, ball screws, drives and four cor-
ner square chisels. Plate size is limited to a maximum
size 1-1/4” x 6”. Adjustment for zero or three degrees
routing is automatic, but chisels mechanically posi-
tioned for three degree plates only
Option
W Drill Gearbox and Air Motor Adds the ability to also drill holes for lever locks with
geared drill boxes. The drills operate at the same
time as the 2-1/8 bore and do not affect cycle time.
Each drilling pattern requires a different gear box, fit-
ted with a direct coupled air motor which are priced
below.With the direct coupled design, door width
minimum is 18". Changeover from one pattern to
another takes approximately 5 minutes.
Option
W1 Sargent 4375C Drill Gearbox with Air motor See Above (Option W)

Overview of the Commander III System
KVAL Commander III Operation Manual
1-4
Option
W2 Best 93K (Cylindrical) Gearbox with Air motor See Above (Option W)
Option
W3 Schlage “D” Serial #792 Drill Gearbox with Air motor See Above (Option W)
Option
W4 Yale 80-7150-0047-010 Drill
Gearbox with Air motor See Above (Option W)
Option
W5 Corbin/Russwin (VT30458) Drill Gearbox with Airmotor See Above (Option W)
Option Title Description

Overview of the Commander III System
1-5
KVAL Commander III Operation Manual
About this Manual
This manual is part of a package delivered with the machine line.
Integration Package includes the following:
Operation Manual includes the following:
Service Manual includes the following
Chapter Title Description
1Introduction Descriptions of Machine Line and
Safety Information.
2About KvalCAM Descriptions of the KvalCam user
interface.
3Operation Inter- face Descriptions of how to power machine line, and operator inter-
face user screens.
4Calibration Descriptions of Calibration Rou-
tines and how to use the interfaces
5Tour of Machine Identification and descriptions of
the machine assemblies.
Chapter Title Description
1Introduction Safety Information.
2System IT Admin-
istration Descriptions of the PLC system, and computer system.
3Maintenance Maintenance steps for the
machine line
4Troubleshooting Troubleshooting tips and theory of
operation.
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 1-20.

Safety First!
KVAL Commander III Operation Manual
1-6
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 1-20.
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!
1-7
KVAL Commander III Operation Manual

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 elec-
trical and air pressure systems. This should be
done in accordance with applicable state and/
or federal code requirements.
Before Conducting Maintenance
Safety First!
KVAL Commander III Operation Manual
1-8

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!
1-9
KVAL Commander III Operation Manual

Safety First!
KVAL Commander III Operation 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.
To Lockout the This Machine
1. Assess the equipment to fully understand all energy sources (multiple electrical sup-
plies, air supply and pressure, spring tension, weight shifts, etc.).
2. Inform all affected personnel of the eminent shutdown, and the duration of the shut-
down.
3. Obtain locks, keys, and tags from your employer’s lockout center.
4. Disconnect power:
a.Turn the disconnect switches on the main electrical panel to the OFF position.
Then pull out the red tab and place a padlock through the hole. Place your tag
on the padlock, as per the tagout guidelines below. (see illustration below).
When multiple people
are working on the
machine, each person
needs to have a lock on
the handle in the extra
holes provided.
b.Turn the disconnect switch on the larger high-frequency panel to the OFF
position. Then pull out the red tab and place a padlock through the hole. Place
your tag on the padlock, as per the tagout guidelines below.