Kval DL-NCD User manual

Innovation, Quality & Honesty
Operation Manual
Published: October 21, 2019
DL-NCD Door Lite System
Operation
Operation Manual

KVAL DL-NCD
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-193-1-OPKvalCam
DL-NCD is trademark of Kval Incorporated.
Copyright 2019 Kval Incorporated. All rights reserved.
Beckhoff®, TwinCAT 2,TwinCat 3, and EtherCat®are registered trademarks and are
licensed 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
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Kval Incorporated
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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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• Email: [email protected]

KVAL DL-NCD Operation Manual
KVAL DL-NCD
Your Feedback is Welcome: To help us design products that make your job easier
and your business more successful, we'd like to gain your perspective about your user
experience with our product - that is, the manual, the machinery, the software, etc.
What was easy or difficult to use or to learn? If you could change something about the
design, what would it be? Please email your comments and suggestions for improve-
ment to [email protected]. (NOTE: This is not a customer support email
link. For that, please refer to the Customer Service contact information above.) Thank
you!
http://www.kvalinc.com

KVAL DL-NCD
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 res 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
KVAL DL-NCD Operation Manual
Chapter 1 Introduction to the DL-NCD
Chapter 1 at a Glance.............................................................. 1-1
Overview of the DL-NCD ......................................................... 1-2
About this Manual .................................................................................1-4
Safety Sheet Sign-Off Sheet.................................................................1-4
Safety First!.............................................................................. 1-5
Safety Sheet Sign-Off Sheet.................................................................1-5
Safety Terminology of Labels................................................................1-5
Safety Guidelines..................................................................................1-5
Lockout-Tagout Guidelines ...................................................... 1-9
Follow the P-R-O-P-E-R lockout rule of thumb.....................................1-9
Lockout Tagout Procedure....................................................... 1-10
Pre-Steps Before Lockout Tagout .......................................................1-10
Lockout Tagout Power ........................................................................1-10
Lockout Tagout Air Supply ..................................................................1-11
Start Maintenance...............................................................................1-11
Post Maintenance Steps .....................................................................1-11
Zero-Energy to Start-Up........................................................... 1-12
Getting Help from KVAL........................................................... 1-14
On-Line Help.......................................................................................1-14
Product Return Procedure..................................................................1-14
How to Download the Service Application ............................... 1-16
Download Application .........................................................................1-16
Safety Sign-Off Sheet .............................................................. 1-19
A Note to the Operator........................................................................1-19
Chapter 2 About KvalCAM
Summary of the KvalCAM Interface ........................................ 2-2
Libraries and Machine Line Screens ....................................................2-2
About the Libraries Screen ...................................................... 2-3
Distinguish between the Door Job and Features Group Libraries ........2-3
Library Screens.....................................................................................2-4
About the Feature Groups and Door Jobs............................................2-5
About the Library Buttons .....................................................................2-5
About Job Creation .................................................................. 2-6
About the Job Name Menu ...................................................................2-7
About the Door Data Menu...................................................................2-7

KVAL DL-NCD Operation Manual
Table of Contents
About the Feature Tree Menu...............................................................2-8
About the Selected Feature Details Menu ............................................2-9
About the Selected Feature Details Menu (Child Level).....................2-10
About the Control Buttons...................................................................2-11
About the Job Preview Screen (2D and 3D).......................................2-12
2 D Screen..........................................................................................2-12
3 D Screen..........................................................................................2-13
About the Machine Line Screen............................................... 2-14
Machine Line Screen ..........................................................................2-14
About Backing up Data and Checking the Revision Status ..... 2-18
Definitions ................................................................................ 2-19
Appendix: Job Preview Examples ........................................... 2-21
Door Face (Lock Preview) ..................................................................2-21
Door Edge (Lock Preview)..................................................................2-22
Door Edge (Hinge Preview) ................................................................2-23
Appendix: About Validation...................................................... 2-24
About the Validation Screen ...............................................................2-25
Outline ................................................................................................2-25
About the LiteCutout Feature Detail ........................................ 2-26
Process...............................................................................................2-26
About the LiteCutout Screen...............................................................2-29
About the Work Area Coordinates......................................................2-30
Sample Oval Cut.................................................................................2-30
Chapter 3 Operation of the Machine Line
About the DL-NCD................................................................... 3-2
About the DL-NCD Process..................................................... 3-3
Initial Powering Operations for the Machine Line .................... 3-4
Operator’s Station.................................................................................3-4
How to Power Up the Machine Line .....................................................3-5
Home the Machine Line........................................................................3-6
How to Power Down the Machine.........................................................3-6
About Emergency Shutdown and Recovery .........................................3-7
To Resume Normal Operation after an E-Stop .....................................3-7
Other Safety Controls ...........................................................................3-7
Machine Line Start Summary................................................... 3-8
About Machine Status Feedback ............................................. 3-10
About the DL-NCD Screens..................................................... 3-11

Table of Contents
KVAL DL-NCD Operation Manual
Screen Tabs........................................................................................3-11
About the Main Control Screen................................................ 3-12
About the Main Control Section ..........................................................3-12
............................................................................................................3-13
About the Width Adjust and Feed Control ..........................................3-14
About the DL-NCD Manual Servo Control Screen................... 3-16
Manual Control Operation...................................................................3-17
About Manual Tool Changer Control...................................................3-18
About the Main Control Section ..........................................................3-19
About Tool Usage .................................................................... 3-20
About the Tool Path Preview Test Tab ..................................... 3-21
About the Tool Config Tabs...................................................... 3-22
General Operating Controls................................................................3-22
Unlock the Tool Slot Configuration......................................................3-23
About the Tool Pop-up Screens ..........................................................3-23
About Tool Locations ..........................................................................3-24
About Using Tool Configuration ..........................................................3-25
Measuring Tool Length .......................................................................3-25
About Entering Data into the Pop-up Menu........................................3-26
About the Lock Block Tab ........................................................ 3-27
About the Status and Log Screens .......................................... 3-28
About the Status Screen .....................................................................3-28
About the Log Screen .............................................................. 3-29
Appendix: Description of the Six Light Panel .......................... 3-30
Appendix: About Backing up the Data ..................................... 3-31
Chapter 4 Calibration of the Machine Line
About Calibration ..................................................................... 4-2
About the Calibration Menus and the Calibration Reference Cut .........4-2
Before you Calibrate .............................................................................4-2
About the Calibration Tabs....................................................... 4-3
Access to the Calibration Adjustments .................................................4-3
Unlock the Calibration (Option).............................................................4-4
Enter a Positive or Negative Number? .................................... 4-5
Door Edge Axis Directions (Option)......................................................4-5
Door Face Axis Directions ....................................................................4-5
How to Enter Calibration Data ................................................. 4-6

KVAL DL-NCD Operation Manual
Table of Contents
About The Calibration Box....................................................................4-6
About Restore Points............................................................................4-7
About the DL-NCD Calibration Screen .................................... 4-8
DL-NCD Calibration Screen..................................................................4-8
Calibration Selections ...........................................................................4-8
About Calibration Sequence .................................................... 4-9
Calibrate the Length and Width ............................................................4-9
Process to Calibrate the Length and Width ..........................................4-9
Step 2: Calibrate the Face Tools.............................................. 4-11
Process to Calibrate the Face Tools ...................................................4-11
Step 3: Calibrate the Face Carriage ........................................ 4-12
Before Calibration ...............................................................................4-12
Face Carriage Axes Calibrations ........................................................4-12
Process to Calibrate the Face Carriage Head ....................................4-13
Face Axis Direction.............................................................................4-13
Step 4: Calibrate the Lock Edge Probe (Option)...................... 4-14
Lock Edge Probe ................................................................................4-14
Before Probe Depth Calibration..........................................................4-14
Process to Calibrate the Probe Depth ................................................4-15
Step 5: Calibrate Lock Edge Tools (Option)............................. 4-16
About the Edge Carriage Axis ............................................................4-16
Process to Calibrate the Lock Edge Tool............................................4-16
Step 6: Calibrate the Tool Holder............................................. 4-17
About the Manual Tool Change Mode ................................................4-17
............................................................................................................4-17
Axis Direction......................................................................................4-18
About the Step Sequence ...................................................................4-18
Process to Calibrate the Tool Holder ..................................................4-18
Step 7: Calibrate the Slug Knockout ........................................ 4-20
Process to Calibrate the Slug Knockout .............................................4-20
Step 8: Calibrate the Clamp..................................................... 4-21
Process to Calibrate the Clamp Assembly .........................................4-21
Step 9: Calibrate the Door Stop ............................................... 4-22
About the Stop 1 Calibration ...............................................................4-22
Appendix: Servo Motor Drive Assembly Locations.................. 4-23
Chapter 5 Tour of the DL-NCD
Top View .................................................................................. 5-2

Table of Contents
KVAL DL-NCD Operation Manual
Operator’s Station.................................................................... 5-3
About Side A and Side B ......................................................... 5-4
Around the Machine................................................................. 5-5
About Indicator Lights ...........................................................................5-5
Option A: About Air Nozzles .................................................................5-5
About Sensors ......................................................................................5-6
Homing and Limit Sensors....................................................................5-7
About the Door Stop System ................................................................5-8
About the Probes .................................................................... 5-9
About the Probe Assemblies ................................................................5-9
About the Cutter Head with Optional Side Drill Assembly ....... 5-10
About the Tool Holder Rack ..................................................... 5-11
Removing the Tool Holder from the Cutter Head..................... 5-12
Changing a Tool Bit and Using Tool-Change Tightening Fixture ........5-13
How to Change a Tool Bit ................................................................5-14
About Field Safety Scanners ................................................... 5-16
About the Drop-Out Area ......................................................... 5-17
Drop-Out: Slide Style ..........................................................................5-17
Drop-Out: Box Style ............................................................................5-17
About the Electrical Panels...................................................... 5-18
About the Frame Node .......................................................................5-20
About the Cutter Node........................................................................5-20

KVAL DL-NCD Operation Manual
Table of Contents