Kval Commander III User manual

Innovation, Quality & Honesty
Operation Manual
Published: 12/22/22
Commander III Operation Manual
With KvalCAM®
Commander III Door System

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
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this information, please call Kval Technical Support at [phone] or fax [phone].
Manual Name: Commander III Door System Operation 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
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reserved. Reference to these products is not intended to imply affiliation with or sponsorship of
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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
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
KvalCAM 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 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-
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.
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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
bout this Manual ...................................................................................1-5
Operation Manual .................................................................................1-5
Service Manual.....................................................................................1-5
KvalCAM Reference Manual ................................................................1-6
Safety Sheet Sign-Off Sheet.................................................................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
Chapter 2 Operation of the Commander III

Commander III
Table of Contents
About the Commander III Process........................................... 2-2
Summary of Machining a Door ................................................ 2-3
Start the Process ..................................................................................2-3
Load Door Job from KvalCAM..............................................................2-3
Load Door.............................................................................................2-4
Set-Up Front Section and Machine the Door........................................2-5
Powering Operations for the Commander III ........................... 2-6
How to Power Up the Commander III...................................................2-6
Home the Commander III .................................................................... 2-7
How to Power Down the Commander III ..............................................2-7
Emergency Shutdown and Recovery ...................................................2-8
About Machine Status Feedback............................................. 2-9
Summary of the KvalCAM Interface ........................................ 2-10
Libraries and Machine Line Screens ..................................................2-10
Screen Tabs........................................................................................2-10
About the Main Control Screen................................................ 2-11
Machine Controls Section........................................................ 2-12
About the Main Control Section..........................................................2-13
About Sequence Control Section........................................................2-14
About Width Adjust .............................................................................2-14
About Carriage Control.......................................................................2-15
About Ball Catch.................................................................................2-16
About Speed Control ..........................................................................2-16
Machine Feedback and Machine Controls .............................. 2-17
About the Top Feedback Bar ..............................................................2-18
About Hinge Tasks Control .................................................................2-18
Hinge Block Descriptions....................................................................2-19
About the Background Colors.............................................................2-19
Shelf Pin Configure and Jamb Stop Section.......................................2-20
Hinge Section Enable or Disable........................................................2-20
Jamb Stop................................................................................................................ 2-21
Jamb Stop Spacers ............................................................................2-21
About the Manual Servo Control Screen ................................. 2-23
Manual Servo Control.........................................................................2-24
Lock Head Movement.........................................................................2-24
Outfeed Stop.......................................................................................2-25
Hinge Carriage....................................................................................2-25
Hinge Head Movement.......................................................................2-26
About the Tool Config Tabs...................................................... 2-27
Unlock the Tool Slot Configuration......................................................2-28

Table of Contents
Commander III
About Using Tool Configuration ..........................................................2-28
Enable or Disable Tool........................................................................2-29
About Hinge Tool Configuration ............................................... 2-30
Tool Config Parameter Definitions ......................................................2-30
About Lock Tool Configuration................................................. 2-32
Summary of the Lock Tool Config.......................................................2-32
About the Lock Edge Bore Config ......................................................2-33
About the Lock Edge Plate Config......................................................2-33
About the Function Drills Config .........................................................2-34
About the Face Bore Config ...............................................................2-34
About the Burn Chipout Buttons .........................................................2-35
About the Ball Catch Configuration.......................................... 2-36
About the Tool Path Preview Test Screen................................ 2-37
About the Status Screen.......................................................... 2-38
About the Log Screen.............................................................. 2-39
Chapter 3 Calibration of Commander III
Chapter 3 at a Glance.............................................................. 3-1
About Calibration ..................................................................... 3-2
About the Calibration Menus and the Calibration Reference Cut.........3-2
Before you Calibrate.............................................................................3-2
Flow Chart of Calibration .....................................................................3-3
About the Calibration Tabs....................................................... 3-4
Access to the Calibration Adjustments .................................................3-4
Unlock the Calibration (Option).............................................................3-5
How to Enter Calibration Data ................................................. 3-6
About The Calibration Box....................................................................3-6
About Restore Points............................................................................3-7
Enter a Positive or Negative Number? .................................................3-7
Axis Direction for Front Section ............................................................3-7
Axis Direction for Back Section.............................................................3-8
Suggested Order of Calibration ............................................... 3-9
Start with a Right Hand Door................................................................3-9
Machine a Left Hand Door....................................................................3-9
About the Calibration Screens ................................................. 3-10
Summary of Calibrations ....................................................................3-10
Opt FC Added Calibrations .................................................................3-11
Summary of Calibrations for Opt FC...................................................3-11

Commander III
Table of Contents
Hinge Head (Over All).........................................................................3-12
Hinge Tools .........................................................................................3-13
Chisels Calibration..............................................................................3-14
Hinge Carriage Location.....................................................................3-16
Lock Head...........................................................................................3-17
Opt FC: Commander III Faceplate and Chisel Calibrations................3-18
Lock Head General.............................................................................3-18
Axis Calibration Direction....................................................................3-19
Plate Router Calibration (Back Section) .............................................3-19
Chisel Calibration (Back Section) .......................................................3-20
Door Stops..........................................................................................3-20
Fast and Slow Lock Plate Timing........................................................3-21
About Lock Plate Timing Calibration...................................................3-22
Feed System Timing...........................................................................3-22
H-Block Display and Jamb Adjustments .............................................3-23
Door and Jamb Depth Adjustment Mapping .......................................3-24
Special Options (Calibrations) ................................................. 3-26
Thickness Feeler Option.....................................................................3-26
Thickness Feeler Calibration ..............................................................3-26
Process to Calibrate Thickness Feelers .............................................3-26
Chapter 4 Tour of the Commander III
Operator’s Tour ........................................................................ 4-2
Top View ...............................................................................................4-2
In-Feed Section: ...................................................................................4-3
Front Section ........................................................................................4-4
About the Operators Station ................................................................4-5
Hinge Carriage......................................................................................4-6
Back Section:........................................................................................4-7
Option FC: CNC Faceplate and Chisels...............................................4-8
Out-Feed:..............................................................................................4-9
About the Electrical Panels...................................................... 4-10
The Main Electrical Panel:..................................................................4-10
The High Frequency Panel.................................................................4-11
About the Nodes ...................................................................... 4-12
Typical Block Diagram of Network Connections .................................4-12
Graphical Sample of Node Connections and Power Distribution .......4-13
Description of the Light Tower ................................................ 4-14
About Switches and Sensors................................................... 4-15
Options .................................................................................... 4-17

Table of Contents
Commander III
Option ND: Narrow Door Fence..........................................................4-17
Option W: Lever Lock Drill (Function Drill)..........................................4-18
Option: Thickness Feelers ..................................................................4-19
Option BC: Ball Catch.........................................................................4-20
Option SJ: Split Jamb .........................................................................4-21

Commander III
Table of Contents