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
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Manual Part Number: DOC-202_3-OPKvalCAM
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KVAL Commander III Operation Manual
KVAL Commander III Operation Manual
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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
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updates of such computer application and documentation.
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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