Kval DL-NCD Operation manual

Innovation, Quality & Honesty
Operation and Service Manual
Published: 8/21/2015
DL-NCD Door Light Cut-Out
Machine

KVAL DL-NCD 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: 193_OPSRV_DLNCD_V2
The DL-NCD Door Light Cut-Out System is a trademark of Kval Incorporated.
Copyright 2015 Kval Incorporated. All rights reserved.
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KVAL DL-NCD Operation Manual
KVAL DL-NCD Operation Manual
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KVAL DL-NCD Operation Manual

KVAL DL-NCD Operation/Service Manual
Table of Contents
Chapter 1 Introduction to the DL-NCD
Chapter 1 at a Glance.............................................................. 1-1
Overview of the DL-NCD ......................................................... 1-2
About this Manual .................................................................................1-2
Safety First!.............................................................................. 1-3
Safety Sheet Sign-Off Sheet.................................................................1-3
Safety Terminology of Labels................................................................1-3
Safety Guidelines..................................................................................1-3
Lockout Tagout Procedure....................................................................1-7
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9
Zero-Energy to Start-Up........................................................... 1-10
Zero-Energy State to Start-Up to Operating State ..............................1-10
Getting Help from KVAL........................................................... 1-12
On-Line Help.......................................................................................1-12
Product Return Procedure..................................................................1-12
How to Download the Service Application ............................... 1-14
Download Application .........................................................................1-14
Safety Sign-Off Sheet .............................................................. 1-17
A Note to the Operator:.......................................................................1-17
Chapter 2 Operation of the DL-NCD
Operator’s Tour........................................................................ 2-2
About Sensors ......................................................................................2-4
About Motion of Servo Motors: X,Y, Z, and W ......................................2-5
About the Door Stop System ................................................................2-6
About the Tool Holder ...........................................................................2-6
How to Change a Tool Manually ...........................................................2-7
Changing a Tool Bit and Using Tool-Change Tightening Fixture ..........2-8
About Air Nozzles ...............................................................................2-11
About Indicator Lights .........................................................................2-11
About the Electrical Panels.................................................................2-12
About the Cutter Head........................................................................2-14
About the Drop Out Area ....................................................................2-15
Description of the Six Light Panel ......................................................2-16
Option G: About the Barcode Scanning Hardware with Stationary Reader2-17
Quick Start Description ............................................................ 2-19

DL-NCD Door Light Machine
Powering Up and Down the DL-NCD ...................................... 2-21
How to Power Up the DL-NCD ...........................................................2-21
How to Home the DL-NCD .................................................................2-22
How to Power Down the DL-NCD.......................................................2-23
About Emergency Shutdown and Recovery .......................................2-23
.................................................................... E-Stop Master Shut OFF2-23
To Resume Normal Operation after an E-Stop ...................................2-23
Description of User Interface Screens..................................... 2-24
About the Operators Station ...............................................................2-24
About the Out-Feed Food Pedal.........................................................2-24
Screen Selection Menu Map...............................................................2-25
Machine Feed Back ............................................................................2-26
About the Main Screen ............................................................ 2-27
About Setup Screens............................................................... 2-32
About Calibration Data........................................................................2-32
Running a Reference Cut ...................................................................2-32
Entering Calibration Data....................................................................2-32
About the Machine Calibration Screen ...............................................2-33
About the Door Width Preset Screen..................................................2-36
About Manual Operation.......................................................... 2-37
About the Diagnostic Screen ................................................... 2-40
Chapter 3 System IT Administration
System IT Administration......................................................... 3-2
About the DL-NCD Computer ...............................................................3-2
Connections on the PLC.......................................................................3-2
Backing up the Computer .....................................................................3-3
About Remote Connection to KVAL Service.........................................3-3
Updating Door Template Files ................................................. 3-4
Generic Lock Template .........................................................................3-4
Generic Rectangle Template (With Round Top Option)........................3-5
Generic Twin Rectangle Template (With Round Top Option) ...............3-6
Template for Specials ...........................................................................3-7
DL-NCD Barcode Setup .......................................................... 3-9
Configuration File Description...............................................................3-9
Configuration Code Samples..............................................................3-10
Chapter 4 Maintenance of the DL-NCD

KVAL DL-NCD Operation/Service Manual
Maintenance Schedule ............................................................ 4-2
Daily, Monthly, Six Month Maintenance ................................................4-2
Lubrication Schedule ...........................................................................4-3
Lubrication Requirements........................................................ 4-4
Linear Bearings, Flange Bearing, and Pillow Blocks ............................4-4
Gear Motor Lubrication Requirements..................................................4-5
Ball Screws (If Applicable) ....................................................................4-5
Description of Air Input System ............................................................4-5
Adjusting the Air Line Lubricator...........................................................4-6
Priming the Air Line Lubricator .............................................................4-6
Replace the X-Axis Self Lubricator .......................................................4-6
Lubrication Points .................................................................... 4-9
Frame and Feed Through.....................................................................4-9
Cutter Head ..........................................................................................4-9
Chapter 5 Troubleshooting the DL-NCD
DL-NCD Sensors ..................................................................... 5-2
How Sensors Work...............................................................................5-2
Troubleshooting Sensors......................................................................5-2
Locations of Sensors from the Out-Feed..............................................5-3
Locations of Sensors from the In-Feed.................................................5-4
Homing and Limit Sensors....................................................................5-5
Troubleshooting the Air Cylinders............................................ 5-6
Adjusting Cylinder Extension Speed:....................................................5-7
Adjusting Cylinder Retraction Speed: ...................................................5-7
Troubleshooting Electrical Problems ....................................... 5-8
If the Power Stops During Normal Operation.......................................5-8
Troubleshooting with the Status Light Panel ........................................5-9

DL-NCD Door Light Machine

1-1
CHAPTER 1 Introduction to the DL-NCD
This chapter provides an overview of the KVAL DL-NCD machine and important safety informa-
tion to follow when operating the machine.
Chapter 1 at a Glance
Chapter 1 at a Glance 1-1
Overview of the DL-NCD 1-2
About this Manual 1-2
Safety First! 1-3
Safety Sheet Sign-Off Sheet 1-3
Safety Terminology of Labels 1-3
Safety Guidelines 1-3
Lockout Tagout Procedure 1-7
Follow the P-R-O-P-E-R lockout rule of thumb. 1-9
Zero-Energy to Start-Up 1-10
Zero-Energy State to Start-Up to Operating State 1-10
Getting Help from KVAL 1-12
On-Line Help 1-12
Product Return Procedure 1-12
Safety Sign Off Sheet 1-15
A Note to the Operator: 1-15
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Overview of the DL-NCD
KVAL DL-NCD Operation/Service Manual
1-2
Overview of the DL-NCD
The DL-NCD is a Numerically-Controlled Door Light Cut-Out Machine equipped with AC servo
control for all four axes of cutting 'X' (Length of the door), 'Y' (width of the door), 'Z' (Depth into
the face of the door), and 'W' (Width adjust of door). The ‘Z’ axis servo control makes it simple to
program for security locks where the face bore is machined to a precise depth and also allows the
operator to reduce the plunge speed to minimize tear out in the bottom face when machining small
diameter holes. When the DL-NCD is used as a drill de-burring on the bottom face may be
required.
The DL-NCD is equipped with an automatic feed and width adjust system to automatically
receive doors, position the door against the stop, clamp the door and start the machining sequence
if the instructions have been downloaded.
The DL-NCD can process doors that vary in height from 6'-8'' and 8'-0.
The direct drive high frequency spindle motor for cutting the door is equipped with an Tool
Holder and access to three (3) additional tool holders placed in a fixture along the fixed side of the
machine. Programs can call for an automatic tool change, feed speed, and RPM adjustment for
wood, fiberglass or steel doors.
Individual door light patterns are created at the machine console, or remotely using a standard PC.
The DL-NCD includes an industrial PC with a standard Ethernet connection for file transfer and
library backup, as well as internet, phone support, and updates from Kval.
About this Manual
This manual contains operation information and service and maintenance information.
It includes identification of machine assemblies, power-up and power-down steps, and informa-
tion about using the user interface.
The Troubleshooting and Maintenance sections are directed toward qualified service technicians.
TABLE 1.
Title Part Number
DL-NCD Operation and Service Manual 193_OPSRV_DLNCD_V1