alliance series operating instructionsoperating instructions. face. for small complex cuts on a...
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Innovation, Quality & Honesty
Operating InstructionsPublished: 9/24/08
Alliance Series
Introduction
IntroductionThis chapter provides a description of the Alliance Series product and identifies safety guidelines to ensure personnel safety and proper equipment use.
Overview of the Alliance Series
The Alliance System functions as a single door machine with multiple stations controlled from a central console. Integrated KVAL software tracks each door as it progresses, automatically setting up the next station just as the door arrives. This allows the Alliance to machine five different doors for five different specifications simultaneously; no setup time is required between doors. Average productivity is one minute door-to-door for hinges and cylin-drical or mortise locks:
• Squared hinges with screw holes.• Cylinder locks with screw holes.• Mortise locks with function holes.• Card locks.• Auto routing and squaring for vision panels.• Viewer holes.• T-Strikes.• Flush bolts including deep drills to 12”.• End detailing for closers, holders
Alliance Series a-a
a-b Alliance Series
Table of Contents
CHAPTER 1 ........................................................................ The Alliance Line 1-1Tour of the Line ............................................................................................... 1-3Quick Start ....................................................................................................... 1-4
How to load a door stack: .......................................................................... 1-6Typical Alliance Product flows .................................................................. 1-7
Single Stack Feed ................................................................................... 1-7Dual Stack Feed ...................................................................................... 1-7Single Door Feed .................................................................................... 1-8External processing ................................................................................. 1-8Removing Single Doors from the process flow ...................................... 1-9Stack Manipulation ................................................................................. 1-9
Mid-Cycle Shutdown and Recovery .............................................................. 1-11Causes of Mid-cycle shutdown ................................................................ 1-11Recovery from Mid-cycle shutdown ....................................................... 1-11
How to re-power a shutdown down machine: ...................................... 1-12How to Manually remove uncompleted doors from the line: ............... 1-14Manual Feed and Width control using the KVAL2006 Program .......... 1-18
CHAPTER 2 ...................................................The KVAL 2006 User Interface 2-1Launching the KVAL 2006 User Interface ............................................. 2-1KVAL 2006 User Interface Visual Tour ................................................ 2-1
Keystroke Shortcuts ................................................................................... 2-2Entering Data ............................................................................................. 2-2
CHAPTER 3 ......................................................................................ON-2010 3-1Door Stack Access ........................................................................................... 3-3
To Enable the Door Stack Access Mode: ............................................... 3-3To Disable the Door Stack Access Mode. .............................................. 3-4
ON-2010 - Operator’s Tour .............................................................................. 3-5Operators Station: ............................................................................................ 3-5
Control Panel ............................................................................................. 3-5Touch Screen .................................................................................................... 3-6
OK to Home ............................................................................................... 3-6Navigation & Control ............................................................................. 3-6
Main Menu REMOTE ............................................................................... 3-7Feed Mode .............................................................................................. 3-7Manual Feed: .......................................................................................... 3-7Door Data ................................................................................................ 3-8
Alliance Series
Stack Control: ....................................................................................... 3-10Navigation ............................................................................................. 3-10
Main Menu LOCAL ................................................................................ 3-11Running Data: ....................................................................................... 3-11Door Width Entry: ................................................................................ 3-12How to change a door width preset: ..................................................... 3-13Entering Fractional Values: ................................................................... 3-14Lift: Move and Mode Control ............................................................... 3-14Stack Control: ....................................................................................... 3-14Feed Mode ............................................................................................ 3-16Navigation ............................................................................................. 3-16Ready Enter Data .................................................................................. 3-16
How to Run a Door in Manual Local Mode: ........................................... 3-17Manual Mode ........................................................................................... 3-18
Reset Sequence: .................................................................................... 3-18Forklift Control: .................................................................................... 3-18Carriage Control: .................................................................................. 3-18Stack Control: ....................................................................................... 3-19Feed Mode: ........................................................................................... 3-19
Maintenance -1 ........................................................................................ 3-20Data: ...................................................................................................... 3-20Change Position: ................................................................................... 3-20Feed Mode ............................................................................................ 3-20Manual Feed: ........................................................................................ 3-20Navigation: ............................................................................................ 3-20
Maintenance -2 ........................................................................................ 3-21Touch Screen view adjustments: .......................................................... 3-21Navigation: ............................................................................................ 3-21
Machine Data ........................................................................................... 3-22Technical Support .................................................................................... 3-22
Homing the ON-2010 .................................................................................... 3-23To Home the ON-2010 ......................................................................... 3-23
CHAPTER 4 ............................................................ Calibrating the ON-2010 4-1
CHAPTER 5 ........................................................................................... FACE 5-1FACE - Operator’s Tour: .................................................................................. 5-3
Control Panel .......................................................................................... 5-3Cutting Head ........................................................................................... 5-4
Touch Screen .............................................................................................. 5-5Main Screen ............................................................................................ 5-5Manual Run Screen ................................................................................. 5-6
Homing the Face .............................................................................................. 5-7
Alliance Series
To Home the Face ................................................................................... 5-7Router Collets .................................................................................................. 5-9
Tool Insertion .......................................................................................... 5-9Collet Maintenance ................................................................................. 5-9
CHAPTER 6 ................................................................. Calibrating the FACE 6-1How to modify a Parameter: ............................................................................ 6-2Parameters ........................................................................................................ 6-4
Tool size and Cutting Depth ...................................................................... 6-4Top Main Router ..................................................................................... 6-4Top Router Depth .................................................................................... 6-4Bottom Main Router ............................................................................... 6-4Bottom Main Router Depth .................................................................... 6-4D1 Top .................................................................................................... 6-4D1 Top Depth .......................................................................................... 6-4D1 Bottom ............................................................................................... 6-5D1 Bottom Depth .................................................................................... 6-5D2 Top .................................................................................................... 6-5D2 Top Depth .......................................................................................... 6-5D2 Bottom ............................................................................................... 6-5D2 Bottom Depth .................................................................................... 6-5
Automated Tool Selection .......................................................................... 6-6D2 Neg .................................................................................................... 6-6D2 Pos ..................................................................................................... 6-6
Cut Location .............................................................................................. 6-7Top Main Router X ................................................................................. 6-7Top Router Y ........................................................................................... 6-7D1 X ........................................................................................................ 6-8D1 Y ........................................................................................................ 6-8D2 X ........................................................................................................ 6-9D2 Y ........................................................................................................ 6-9Left Hand X .......................................................................................... 6-10Right Hand X ........................................................................................ 6-10SSX1: .................................................................................................... 6-11SSX2: .................................................................................................... 6-11SSX3 ..................................................................................................... 6-11SSX4 ..................................................................................................... 6-11SSX5 ..................................................................................................... 6-11
Left Stop Calibrations .............................................................................. 6-12Left Stop 1 ............................................................................................. 6-12Left Stop 2 ............................................................................................. 6-12Left Stop 3 ............................................................................................. 6-13Left Stop 4 ............................................................................................. 6-13Left Stop 5 ............................................................................................ 6-14
Alliance Series
Left Stop 6 ............................................................................................ 6-14Left Stop 7 ............................................................................................ 6-15Left Stop 8 ............................................................................................ 6-15Left Stop 9 ............................................................................................ 6-16Left Stop 10 .......................................................................................... 6-16Left Stop 11 .......................................................................................... 6-17
Right Stop Calibrations ............................................................................ 6-18Right Stop 1 .......................................................................................... 6-18Right Stop 2 .......................................................................................... 6-18Right Stop 3 .......................................................................................... 6-19Right Stop 4 .......................................................................................... 6-19Right Stop 5 .......................................................................................... 6-20Right Stop 6 .......................................................................................... 6-20Right Stop 7 .......................................................................................... 6-21Right Stop 8 .......................................................................................... 6-21Right Stop 9 .......................................................................................... 6-22Right Stop 10 ........................................................................................ 6-22Right Stop 11 ........................................................................................ 6-23
CHAPTER 7 ......................................................................... Architect DI-DM 7-1Architect DI-DM - Operator’s Tour 7................................................................. -3
Control Panel: ......................................................................................... 7-3Touch Screen .................................................................................................... 7-4
Main Screen ............................................................................................... 7-4Feed Select .............................................................................................. 7-4Back Section Speed ................................................................................ 7-4Hinge Speed ............................................................................................ 7-4Navigation ............................................................................................... 7-4
Manual Run Screen .................................................................................... 7-5Manual Feed ........................................................................................... 7-5Navigation ............................................................................................... 7-5
Machine Data Screen ................................................................................. 7-6Homing the Architect DI DM .......................................................................... 7-7
To Home the Architect DI DM ............................................................... 7-7Router Collets .................................................................................................. 7-9
Tool Insertion .......................................................................................... 7-9Collet Maintenance ................................................................................. 7-9
CHAPTER 8 ................................................Calibrating the Architect DI-DM 8-1How to modify a Parameter: ............................................................................ 8-2Parameters ........................................................................................................ 8-4
Front Section .............................................................................................. 8-4
Alliance Series
Pocket Definitions ................................................................................... 8-4Hinge Locations ...................................................................................... 8-4
Full Front section Calibration Procedure ................................................... 8-4Pocket Parameters - Predrills .................................................................. 8-5Pocket Parameters - General ................................................................... 8-5Router Diameter ..................................................................................... 8-6
General Front Section: ............................................................................... 8-6HINGE Z Each Pass ............................................................................... 8-6Hinge Outfeed Stop ................................................................................. 8-6Hinge Infeed Stop: .................................................................................. 8-6
Back Section .................................................................................................... 8-7Router ......................................................................................................... 8-7
Router Horizontal, Vertical ..................................................................... 8-7Router Diameter ...................................................................................... 8-7Router Depth ........................................................................................... 8-83 Deg Depth ............................................................................................ 8-8Z Each Pass: ............................................................................................ 8-8
Chisels ........................................................................................................ 8-8Z Offset to Chisel aa ............................................................................... 8-8Deep Mortis ............................................................................................ 8-9DM Diameter .......................................................................................... 8-9Z Ech DM Pass: ...................................................................................... 8-9DM Depth: .............................................................................................. 8-9
Counter Rotating Router .......................................................................... 8-10Cnt Rout Diam (Counter Router Diameter) .......................................... 8-10Cnt Rout Depth: .................................................................................... 8-10
Side Drills ................................................................................................ 8-11Side Drill Z: .......................................................................................... 8-11Side Drill Diam: .................................................................................... 8-11
General Back Section ..................................................................................... 8-12Side Enc. 0 ............................................................................................ 8-12Side Enc. 3DEG .................................................................................... 8-13
How to select a perfectly square door (or one that’s close enough) ........ 8-14Feed System ................................................................................................... 8-15
Infeed RH End check: ........................................................................... 8-15Outfeed LH End check: ........................................................................ 8-16Infeed Stop: ........................................................................................... 8-16
CHAPTER 9 ..........................................................................................EDGE 9-1EDGE - Operator’s Tour ......................................................................... 9-3Control Panel One ................................................................................... 9-4Control Panel Two .................................................................................. 9-5
Homing the EDGE ........................................................................................... 9-7
Alliance Series
To Home the EDGE ................................................................................ 9-7Deep Mortise Collet ......................................................................................... 9-9
Tool Insertion .......................................................................................... 9-9Collet Maintenance ................................................................................. 9-9
CHAPTER 10 ............................................................ Calibrating the EDGE 10-1How to modify a Parameter: .......................................................................... 10-2Parameters ...................................................................................................... 10-4
Lock Location .......................................................................................... 10-4Lock Location RH ................................................................................ 10-4Loch Location LH ................................................................................. 10-4
Stops ......................................................................................................... 10-5Left Stop ................................................................................................ 10-5Middle Stop ........................................................................................... 10-5Right Stop ............................................................................................. 10-6 Left Outboard Stop .............................................................................. 10-6 Right Outboard Stop ............................................................................ 10-7
Deep mortise ............................................................................................ 10-7DM Vertical ........................................................................................... 10-7DM Diameter ........................................................................................ 10-8Deep Mortise X: .................................................................................... 10-8Depth parameters .................................................................................. 10-8
Plate Router .............................................................................................. 10-9Router Vert Offset (Vertical Offset) ...................................................... 10-9Router Diam (Diameter) ....................................................................... 10-9Depth parameters .................................................................................. 10-9
Counter Rotating Router ........................................................................ 10-10Cnt Rout Vert, Cnt Rout Horiz (Vertical, Horizontal) ........................ 10-10Cnt Rout Diam (Counter Router Diameter) ........................................ 10-10
Side Drills .............................................................................................. 10-11Chisels .................................................................................................... 10-11Predrills .................................................................................................. 10-12
Predrill 1 X offset and Predrill 1 vert offset ........................................ 10-12Depth parameter .................................................................................. 10-12
CHAPTER 11 .................................................................................. DL-NCC 11-1DLNCC - Operator’s Tour ............................................................................. 11-3Operators Station: .......................................................................................... 11-3
Power ....................................................................................................... 11-3Touch Screen .................................................................................................. 11-4
Main Screen ............................................................................................. 11-4Feed ...................................................................................................... 11-4
Alliance Series
Automatic Tool Changer .......................................................................... 11-5Tool Management ................................................................................. 11-6Status indicators: ................................................................................... 11-7Control: ................................................................................................. 11-7Navigation ............................................................................................. 11-7
Tool Changer ............................................................................................ 11-8Motor Status .......................................................................................... 11-8Tool Changer Status .............................................................................. 11-9Navigation ............................................................................................. 11-9
Manual Run ............................................................................................ 11-10Feed Controls ...................................................................................... 11-10Navigation ............................................................................................11-11
Changing a Tool Manually ..................................................................... 11-13To Change a Tool Manually ................................................................ 11-13
Changing a Tool Bit ............................................................................... 11-14To Change a Tool Bit .......................................................................... 11-14
Homing the DLNCC .................................................................................... 11-17To Home the DLNCC ......................................................................... 11-17
CHAPTER 12 .........................................................Calibrating the DL-NCC 12-1Calibrating the DL-NCC Tool Changer ................................................... 12-1
Determining Which Calibration Stage to Use ...................................... 12-1Preparing to Calibrate the Tool Changer .............................................. 12-1
Tool Calibration, Stage 1: Calibration Bolt ............................................. 12-3Tool Calibration, Stage 2: Tool Offset ..................................................... 12-8Tool Calibration, Stage 3: Tool Holders ................................................ 12-12Calibrating Cut Accuracy ...................................................................... 12-14
To Calibrate the Cut Accuracy ............................................................ 12-14Correcting Cut Accuracy Problems ....................................................... 12-17
CHAPTER 13 ........................................................................................ RAIL 13-1Door Stack Access ......................................................................................... 13-3
To Enable the Door Stack Access Mode: ............................................. 13-3To Disable the Door Stack Access Mode. ............................................ 13-4
Rail - Operator’s Tour .................................................................................... 13-5Operators Station: .......................................................................................... 13-6
Control Panel ........................................................................................... 13-6Touch Screen .................................................................................................. 13-7
OK to Home ............................................................................................. 13-7Navigation & Control ........................................................................... 13-7
Main Menu REMOTE ............................................................................. 13-8Feed Control ......................................................................................... 13-8
Alliance Series
Stack Control ........................................................................................ 13-8Navigation ............................................................................................. 13-9
Main Menu LOCAL .............................................................................. 13-10Door Length Entry .............................................................................. 13-10How to change a door length preset: .................................................. 13-11Entering Fractional Values: ................................................................. 13-12Feed Control ....................................................................................... 13-12Stack Control ...................................................................................... 13-12Navigation ........................................................................................... 13-13Ready Enter Data ................................................................................ 13-13
How to Run a Door in Manual Local Mode: ......................................... 13-14Manual Mode ......................................................................................... 13-15
Reset Sequence: .................................................................................. 13-15Forklift Servo: ..................................................................................... 13-15Stop Servo: .......................................................................................... 13-15Carriage Servo: ................................................................................... 13-16Stack Control ...................................................................................... 13-16Feed ..................................................................................................... 13-16Navigation: .......................................................................................... 13-17
Maintenance -1 ...................................................................................... 13-18Servo Position Points: ......................................................................... 13-18ModBus Communication mode: ......................................................... 13-18ModBus Communicating Status: Lift to Rail ..................................... 13-18Touch Screen Program Version .......................................................... 13-18Navigation ........................................................................................... 13-19Troubleshooting .................................................................................. 13-19
Maintenance -2 ...................................................................................... 13-19Touch Screen view adjustments: ........................................................ 13-19Navigation: .......................................................................................... 13-19
Remove Door ......................................................................................... 13-20Feed ..................................................................................................... 13-20 Cross feed system. ............................................................................. 13-20Clamp: Manual Operation .................................................................. 13-21Homing Status and Start Button ......................................................... 13-21Stack Control ...................................................................................... 13-21Reset Sequence: .................................................................................. 13-21
Machine Data ......................................................................................... 13-22Technical Support .................................................................................. 13-22
Homing the RAIL ........................................................................................ 13-23To Home the Rail ................................................................................ 13-23
CHAPTER 14 ...............................................................Calibrating the RAIL 14-1
Alliance Series
CHAPTER 1 The Alliance Line
This chapter provides over all operating instructions for the KVAL Alliance Line.
Alliance Series 1-1
The Alliance Line
1-2 Alliance Series
Tour of the Line
ON-2010
Lift, Flip and Rotate and Stack.
See “ON-2010” on page 3-1 for operating instructions.
FACE
For small complex cuts on a door’s face.
See “FACE” on page 5-1 for operating instructions.
Architect DI-DM
For small complex cuts on the hinge and lock edge of the door.
See “Architect DI-DM” on page 7-1 for operating instructions.
EDGE
For small complex cuts on the lock edge of the door.
See “EDGE” on page 9-1 for operating instructions.
DL-NCC
For large and small complex cuts on a door’s face.
See “DL-NCC” on page 11-1 for oper-ating instructions.
RAIL
For small complex cuts on a door’s top and bottom edge. plus a stacker.
See “RAIL” on page 13-1 for operating instructions.
Tour of the Line
Alliance Series 1-3
Quick Start1.Apply power to the Line.
a.Turn on all compressed lines to all machines.b.Turn on all electrical disconnects for all machines.c.Apply electrical power to all Safety Zones starting with Safety Zone one.
Note: Safety Zones must be turned on in order.
Safety Zone 1
Safety Zone 2
Safety Zone 3
Safety Zone 4
d. Pull out the CONTROL TRANSFORMER switch for each machine in the safety zone.
Each control transformer button should light and each computer should start.
e. Push the START button for each com-puter in the safety zone.
All lights on the Status Light Panel for each machine should be illuminated.
f. If all Safety Zones are powered the Power to the Line process is complete, if not move to the next safety zone and go back to step d.
ControlTransformer
Machine
START
STOP
CONTROL POWER
OVERLOAD RELAY
E-STOP
STOP
START
24VDC
1-4 Alliance Series
Quick Start
2. Launch the KVAL 2006 user interfaceFor each machine:
a. Open the KVAL folder on the computer desktop.b. Double-click the KVAL2006.EXE shortcut. The KVAL 2006 user interface opens (see exam-ple below).
3. Home each machine:a. Remove any doors from the feed system.b. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.c. Click twice on the Home button. The machine should start the homing operation. d.NOTE:While the homing operation is in progress, the Home button changes its label to Homing.
4.
Network Off Network On
On each machine toggle the Network ON/OFF button to ON.
The Alliance line is now ready for work.
Maint
Home
OK
Homing
Home?
Alliance Series 1-5
How to load a door stack:
Top View
Door
Stack 1
Stack 2
Stop DoorStop
DoorStop Door
Stop
When loading Doorsmove doors into themachine all the way to the Door Stops.
When loading Doorsmove doors into themachine all the way to the Door Stops.
Feed
To load doors into the Alliance line:1. Chose the Door Stack 1 or Door Stack 2 to load based on product flow.2.Lower the Stack Lift to the desired height. See “Stack Control:” on page 3-10 for more information.3.Enable the Stack Access mode. See “Door Stack Access” on page 3-3 for more information.4.Load the doors onto the stack lift. Move the doors into the machine until they doors contact the door
stops.5.Disable the Stack Access mode. See “Door Stack Access” on page 3-3 for more information.
The doors are now ready to process.
1-6 Alliance Series
Quick Start
Typical Alliance Product flows
Single Stack Feed
Load DoorsHere
Remove DoorsHere
Use this mode to process a single door stack.
Dual Stack Feed
Load DoorsHere
Remove DoorsHere
HereLoad Doors
Use this mode to process two door stacks.
Alliance Series 1-7
Single Door
Load DoorsHere
Remove DoorsHere
Feed
This mode is typically used for template testing, or for re-processing a door after a a mid-process stream failure.
External processing
Remove Completed Doors Here
ExternalProcess
Normal Process Flow
This mode is used for a door that requires additional processing external to the Alliance line.
1-8 Alliance Series
Quick Start
Removing Single Doors from the process flowRemove Reject
Doors Here
Normal Process Flow
This mode is typically used to remove rejected doors from the process flow.
Stack Manipulation Remove Doors Here
Load Doors
This mode is used for reorienting doors within a door stack Any door in a stack can be flipped, rotated or both.
Alliance Series 1-9
1-10 Alliance Series
Mid-Cycle Shutdown and Recovery
Mid-Cycle Shutdown and RecoveryCauses of Mid-cycle shutdown
Mid-cycle shut down will result if any machine in the line loses power. Possible reasons for a machine can lose power can if:
• An E-Stop is pushed.• A Safety Gate is opened• An active Light Curtain is penetrated.• A Control Transformer button is pushed.• An Electrical Disconnected is turned off.• There is a Power Failure.
Recovery from Mid-cycle shutdown
When a mid-cycle shut down occurs, all door data information stored in the powered down machine is lost. To reload the door data all doors must be cleared from the line. To clear doors from the line:1.Allow the doors in the line past the shutdown machine can continue processing and be removed using
the normal process flow. 2.Re-power the shut down machine. See “How to re-power a shutdown down machine:” on page 1-12
for more details.3.Doors in the line before and in the shutdown machine must be revers fed back through the line and
removed from the infeed end of the ON-2010. See “How to Manually remove uncompleted doors from the line:” on page 1-14 for more details.
The example below shows the process flow if the Edge machine was shutdown.
Let the working machines continue processing. Remove completed Doors Here.
Manually remove uncompleted Doors Here
powered downEdge machine
ON-2010 FACE Arch-DI-DM EDGE DL-NCC RAIL
Alliance Series 1-11
How to re-power a shutdown down machine:
Determine the shut-down cause. Check the Status Light Panel located on the machines opera-tor’s station.
1.If the Control Power light is off: There is no power to the machine.Possible causes: An open disconnect, a blown fuse in the main power line, a tripped circuit breaker external to the machine.Action: Insure the disconnect is ON. If the Control Power light remains off, call the plant maintenance department.
2.If the Overload Relay light is off: Possible cause: A tripped overload relay in one of the machines electrical cabinets.Action: Call the plant maintenance department.
3.If the E-Stop light is off: Possible cause: An E-Stop has been pushed or safety gate is open.Action: Insure all E-Stops are pulled out, and safety gates are closed. If the E-Stop light remains off, call the plant mainte-nance department.Note: Within each safety area all E-Stops must be pulled out and all safety gates must be closed before any machine located in that safety will power up. Safety areas shown at right.
4.If the Stop light is off: Possible cause: The Control Transformer button was pushed in, momentary line power loss, low line power. Action: Insure the Control Transformer button is pulled out. If the Stop light remains off, call the plant maintenance depart-ment. Note: Within each safety area all Control Transformer buttons must be pulled out before any machine located in that safety will power up. Safety areas shown at right.
5.If the Start light is off:Possible cause: The Control Transformer button was pushed in, momentary line power loss, low line power. Action: Push the START button for each computer in the safety zone. If the Start light remains off, call the plant mainte-nance department.
Safety Zone 1
Safety Zone 2
Safety Zone 3
Safety Zone 4
CONTROL POWER
OVERLOAD RELAY
E-STOP
STOP
START
24VDC
Status Panel Lights
1-12 Alliance Series
Mid-Cycle Shutdown and Recovery
6.Enable the servos by starting the homing process:e.
Maint
Home
OKHome?
In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.f.Click twice on the Home button. The machine should attempt to start the homing operation. Since there is a door in the machine the homing process will abort. Use the mouse to click in the message box to clear the message.
Door in machine. Please remove door before homing
[Click to Clear]
ClickHere
The servos are now enabled. This will allow the machine to respond to the Jog commands.7.After the door is removed from the machine complete the homing process.
a. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.b. Click the Home button. This will change the button label to OK to Home?c.CLick the OK to Home? button.d.NOTE:While the homing operation is in progress, the Home button changes its label to Homing.
Maint
Home
OKHome?
Homing
Alliance Series 1-13
How to Manually remove uncompleted doors from the line:
Manually remove uncompleted doors Here
ON-2010 FACE Arch-DI-DM EDGE DL-NCC RAIL
InfeedEnd
When reverse feeding doors through the line both width adjust and feed control must be done manu-ally. Note: Doors of the same width can be reverse as a group.
1. Door out:
Remove DoorHere
ON-2010
a.Reverse feed the door out of the ON-2010’s infeed end.From the main menu select Maintenance. Use the Jog Reverse to reverse feed the door.
b.If all the doors are removed from the line, this process is completed. If not go to the next step.Note: There is no support for the door at the infeed end of the line. Use a roll table or get help.
2. Move the door from FACE to ON-2010:ON-2010 FACE
a.Reverse feed the door from the FACE machine into the ON-2010. See “Manual Feed and Width control using the KVAL2006 Program” on page 1-18 for more information.a.Go to step 1.
Manual Run
JOGREVERSE
1-14 Alliance Series
Mid-Cycle Shutdown and Recovery
3. Move the door from 3rd machine to 2nd machine:FACE Arch-DI-DM
a. Adjust the FACE machine’s width adjust system to accommodate the door in the Arch_DI-DM. See “Manual Feed and Width control using the KVAL2006 Program” on page 1-18 for information.
b.Reverse feed the door from the Arch_DI-DM into the FACE.From the main menu select Maintenance. Use the Jog Reverse to reverse feed the door.
c.Go to step 2.
4. Move the door from EDGE machine to Arch_DI-DM:Arch-DI-DM EDGE
a. Adjust the Arch_DI-DM’s width adjust system to accommodate the door in the EDGE. See “Manual Feed and Width control using the KVAL2006 Program” on page 1-18 for information.
b.Reverse feed the door from the EDGE machine into the Arch_DI-DM. On the Main control panel press the Feed Reverse button.
c.Go to step 3.
5. Move the door from 5th machine to 4th machine:EDGE DL-NCC
a. Adjust the EDGE’s width adjust system to accommodate the door in the DL-NCC.b. The DL-NCC’s clamping mechanism, unlike the other machines in the line, is completely servo controlled. If the door is clamped the width adjust may need to be opened slightly to unclamp the door.
c.Reverse feed the door from the DL-NCC machine into the EDGE. From the main menu select Maintenance. Use the Jog Reverse to reverse feed the door.
d.Go to step 4.
Manual Run
JOGREVERSE
REVERSE
Manual Run
JOGREVERSE
Alliance Series 1-15
6. Determine the path for the door in the RAIL:
• If the door is on the rollers see “Move the door from the Rail to the DL-NCC” below.• If the door is on the cross feed system see “Feeding a door in the Rail to stack #2” below.
Move the door from the Rail to the DL-NCC:DL-NCC RAIL
a. Adjust the 5th machine’s width adjust system to accommodate the door in the 6th machine.
b.Reverse feed the door from the 6th machine into the 5th machine.From the main menu select Maintenance. Use the Jog Reverse to reverse feed the door.
c.Go to step 5.
Feeding a door in the Rail to stack #2.
Stack #1
Stack #2
Cross FeedArea
a.In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.b.Click twice on the Home button. The machine should attempt to start the homing operation. Since there is a door in the machine the homing process will abort. Use the mouse to click in the message box to clear the message.
Door in machine. Please remove door before homing
[Click to Clear]
ClickHere
The Touch Screen button at the lower left portion of the screen should display Door Not in Position.
Manual Run
JOGREVERSE
Maint
Home
OKHome?
DOOR NOTIN POSITION
1-16 Alliance Series
Mid-Cycle Shutdown and Recovery
c.MANUAL
CROSSFEEDFORWARD
Move the door into the End Mill section of the machine using the Manual Crossfeed Forward button on the touch screen. The door must contact the End Mill Door Stop.
End Mill
End Mill
Door Stop
d.OK TO HOME
Press the OK to HOME Touch Screen but-ton at the lower left portion of the screen should display.
The machine should home. When homing is complete the machine will move the door to Stack #2 for removal.The machine is now ready for work.
Alliance Series 1-17
Manual Feed and Width control using the KVAL2006 Program
The first page or pages of the calibration menu display the manual servo jog screens. To get to these screens:
a.On the PC, in the KVAL 2006 interface, click once on the Maint button.b.Click the CAL button.
A message pop up in front of the graphic display area.
Click on the pop-up message to proceed.c.Click the Cal OK? button. The Jog page of the Calibration Menu page appears.
X
X Axis Y Axis Z Axis
Jog X Y and Z
< > < > < >STOP STOP STOP
4000 4000 4000
EXIT
Setup
Calibration
Galil
C:\ \Dataline\Door.dbf\Dataline\Lock.dbf\Dataline\DoorNum.dbf\Dataline\LockDlnc.dbf\Doorlite\DLNC2004.cal\Doorlite\DLNCHome.cal
[Space Bar to Stop]
Calibration Menu
Width
< >STOP
4000
Change Axis
Typical Jog Menu
Change Menu Page
Exit the JogMenu
Axis JogControls
d.Change Axis Use the Change Axis button to find the desired Axis.Face: Width and FeedAll others: Width
e.
Width
< >STOP
4000
Stop
Axis Jog Control
Speed
Start Move(Close)
Start Move(Open)
Move
Example
Speed Adjust(Reduce)
Speed AdjustIncrease
Indicator
Use the Axis Jog Control to move the axis to the desired position.f.Use the Exit button to return to the main menu.
How to use the Axis Jog Control:a.Use Speed Adjust controls to adjust the servo speed to a workable rate.
Note: 4000 is a reasonable place to start.b.Use the Start Move and Stop Move buttons to move the servo axis to the desired location.c.Note: A Start Move button will start a axis in motion. The axis motion will continue until a Stop Move button is clicked.
Maint
Cal
Cal OK?
Calibration and Jog will Abort Program
Hit Esc or exit to cancel
1-18 Alliance Series
CHAPTER 2 The KVAL 2006 User Interface
Use the KVAL 2006 software program to control the Alliance Series. Use the KVAL 2006 software to define and execute door files, which contain the specifications for the cuts the Alliance Series makes on the doors. (Note: The unit of measure for all door specifications is inches.)
Launching the KVAL 2006 User Interface
On the Operator's Station computer, the KVAL 2006 user interface, in addition to other system adminis-tration software, has a shortcut on the desktop in a folder called “KVAL.” To launch the KVAL 2006 user interface, open the KVAL folder and double-click the KVAL2006.EXE shortcut.
KVAL 2006 User Interface Visual Tour
Following is a general overview of the KVAL 2006 user interface functions. Details about the various interface elements are provided in context to the procedures for homing the machine and cutting doors.
Click this button to finish processing the current door, but clear all subsequent door files.
Click this button to download the selected door file. The cutting commences after the door is clamped into the machine
To Home the machine, click “Maint” once, then click the but-ton below it (“Home”).
To enter Calibration mode () click “Maint” twice
These buttons are used to cancel a cut in pro-cess.
These buttons are used while defining or modify-ing door files or cut tem-plates.
Displays either:
• Door files that can be downloaded & run.
• Cut templates that can be assigned to a door file.
• List of templates as assigned to a spe-cific door file.
Displays the specs for a selected door, or for a selected cut.
ViewField
Alliance Series 2-1
The KVAL 2006 User Interface
Keystroke Shortcuts
TABLE 1.
Keystroke Shortcut DescriptionF1 Abort - Stops the downloaded door file from being executed by the Alliance
Series.
Ctrl+F1 Key list - Displays this list
F2 Restart
F4 Barcode Off-On
F8 Download or put on list
F9 Door List Off-On
F10 Esc or Exit
F11 Program Off-On
F6+PROG PROG Copy.dbf
Ctrl+F12 Minimize Screen
F7 Full or Partial Download
Entering Data
When entering data for a door or template, enter the data in the respective field and press the Enter key to proceed to the next field.All measurements are in units of inches.Tip: When entering values, you can type in fractions and let the software calculate the decimal equiva-
lent. For example, if you type “35 7/8” (place a space between “35” and 7/8”) into a parameter field and press the Enter key, the software automatically converts the value to 35.875 inches.
2-2 Alliance Series
CHAPTER 3 ON-2010
This chapter provides operating instructions for the KVAL ON-2010.
Alliance Series 3-1
ON-2010
3-2 Alliance Series
Door Stack Access
Door Stack AccessThis ON-2010 is equipped with Light Curtain safety devices. Breaking the light curtain beam has the same result as pushing an E-Stop. Power is removed from all motors, all servo systems, and all control circuits. When enabled, the Light Curtains do not allow access to the door stacks. To enable access to the door stacks use the Door Stack Access Mode procedure shown below.
To Enable the Door Stack Access Mode:
Light Curtain
Stack Access Area
Light Curtain
Stack Access Area
(RED) (RED)
(YELLOW) (YELLOW)
1.Press the Enable Access button.2.Wait for the Enable Access button and the blue light tower light to flash on and off.3.The Stack Area is available for access.
With Safety Skirt, Entry OK No Safety Skirt, No Entry
CAUTION: At this point there is still power to all motion control systems. • Do not enter the machine any further than the
stack access area indicated in yellow above.• Keep away from the door lift and the vacuum
clamp.• The lift must be equipped with a safety skirt. Do
not enter the stack access area if the safety skirt has been removed.
CAUTION: The Door Stack Access Mode allows access behind the machine’s light curtain safety devices and is for loading and unloading the door stacks ONLY. No maintenance should be performed in this mode. All controlling outputs are frozen. However, POWER IS STILL APPLIED TO ALL MOTION CONTROL SYSTEMS. In this mode a system failure could cause a motion control system to “run away” at full speed. DO NOT PUT YOURSELF IN A MOTION CONTROL SYSTEM’S PATH.
USE EXTREME CAUTION WHEN enabling the Door Stack Access Mode.
Alliance Series 3-3
To Disable the Door Stack Access Mode.
1.Ensure all personal are away from the machine and outside the light curtain.1.Pull out the Enable Access button.
The Enable Access button and the blue light tower light should turn off.The machine is now ready to resume work.
3-4 Alliance Series
ON-2010 - Operator’s Tour
ON-2010 - Operator’s TourInfeed End
Outfeed End
FeedDirection
Top View
Door Lift Door Lift
Stack #1 Stack #2
Rollers
Carriage and Vacuum Clamp
Forklift(Lifts door form rollers)
Operators Station:Control
TransformerStart Machine
START
STOP
Disable LiftVacuumONOFF
Control Panel
• Control Transformer: Applies electrical power to control circuits and computer• Machine START / STOP: Applies electrical power to drive circuits.• Disable Lift: Stops the current process with two exceptions:
a. A “rotate will continue until the rotation is completed.b. A “Flip” will continue until the flip is complete.
• Vacuum: Controls the Vacuum Clamp’s vacuum.
Alliance Series - ON-2010 3-5
Touch ScreenOK to Home
Green ifHoming completed
123.45
MANUAL MODE
page 3-18
FORKLIFT
00:NOT HOMED
O.K. TO HOME
I-40CARRIAGE
00: NO ERROR
00:NOT HOMED00: NO ERROR
I-41
123.45
RDY
RDY
Forklift StatusMessages
Carriage StatusMessages
Position
Indicators
Navigation & Control
• Manual Mode: Opens the Manual Mode screen. See page 3-18 for more details.• O.K. to Home: Starts the homing process.
The OK to Home button has three states:Yellow = OK to HomeRed = Unable to home. The ON2010 has found a condition that prohibits it from homing. Green = Homed.
3-6 Alliance Series
Touch Screen
Main Menu REMOTE
MAINTE-NANCE
page 3-20
GO TO LOCAL
page 3-11
READY
NEW DOOR DATA RUNNING DATA
OK TO FEED-IN
STACK#1
MB: OK
123.45-12.34
NO ACCESS
I-14
PICK-UP
LOAD POS
FLIP ROT STACK#1 XFERSTACK#2FLIP ROT XFER
123.45-12.34
SLOW JOGFORWARD
JOGREVERSE
AUTOFEED
FEEDTHRU
MANUALFEED
STACK#2PICK-UP
LOAD POS
Door
Stack
Navigation
Data
Control
FeedMode
ManualFeed
The Main Menu REMOTE screen allows control of the machine from data received from a remote computer.
Feed Mode
MANUALFEED
AUTOFEED
FEEDTHRU
• Manual Feed: Puts the feed system in manual mode. In the manual mode the feed system is con-trolled by the Manual Feed buttons described below.
• Auto Feed: Puts the feed system in Automatic mode. In this mode the feed system is controlled by the machine’s computer.
• Feed through: In this mode the door will move through the machine without being processed.
Manual Feed:
SLOW JOGFORWARD
JOGREVERSE
• Jog Rev (Jog Reverse): Turns on the feed system in reverse mode if the Feed Mode is set to manual.• Slow: This button when pressed with either Jog Rev or Jog Fwd puts the feed system in slow mode.• Jog Fwd (Jog Forward): Turns on the feed system in reverse mode if the Feed Mode is set to man-
ual.
Alliance Series - ON-2010 3-7
Door Data
READY123.45-12.34
FLIP ROT XFERFLIP ROT STACK#1 XFERSTACK#2
123.45-12.34
NEW DOOR DATA RUNNING DATA
FLIP ROT
Door Length
Door ManipulationIndicators Active Stack
IndicatorsOperation Mode
Indicator
Door Width
Data Transfer
Data for Next Door to be Processed Data for Door in Process
This portion of the display show door data for the door currently being processed, called Running Data, and door data for the next door to be processed, called New Door Data.
• Door Width and Door Length:Displays the programmed door width and door width values.
Door Length
DoorWidth Door
• Door Manipulation Indicators: The Door Manipulation indicators, Flip and Rotate, indicate how the machine will orient the door before the door leaves the machine. The four possible states are shown below.
Flip OFF, Rotate OFF:
No manipulation.
FLIP
LatchSide
HingeSide
Top
Bottom
ROT
Flip ON, Rotate OFF:
The door is flipped on it’s long axis.
FLIP
LatchSide
HingeSide
Top
Bottom
LatchSide
HingeSide
Top
BottomBefore Flip After Flip
ROT
Flip OFF, Rotate ON:
The door is rotated on it’s short axis.
LatchSide
HingeSide
Top
Bottom
LatchSide
HingeSide
Top
BottomBefore Rotate After Rotate
ROTFLIP
Flip ON, Rotate ON:
The door is flipped on it’s long axis, rotated on it’s short axis.
LatchSide
HingeSide
Top
BottomBefore Flip & Rotate After Flip & Rotate
LatchSide
HingeSide
Top
Bottom
FLIP ROT
• Active Stack Indicators: STACK#1STACK#2
3-8 Alliance Series
Touch Screen
Indicates the active door stack. The active stack will be shown as GreenInfeed End
Outfeed End
Stack #1 Stack #2
• Operation Mode Indicator: XFER XFER
The Transfer button (XFER) determines the product flow path. With Transfer OFF the doors flow from Door Stack 1, or Door Stack 2 out to the next machine.
Load DoorsHere
Load DoorsHere
HereLoad Doors
To Next Machine To Next Machine
XFER
With Transfer ON the doors flow from Stack #1 to Stack #2. Typically this mode is used in conjunc-tion with the Door manipulation (see page 3-8) to reorienting doors within a stack.
Remove Doors Here
Load Doors
Stack #1
Stack #2
XFER
Alliance Series - ON-2010 3-9
Stack Control:
Holding this button will raise Stack One’s Door
Lift.
Holding this button will lower Stack One’s Door Lift.
Holding this button will raise Stack Two’s Door
Lift.
Holding this button will lower Stack Two’s Door Lift.
NavigationMAINTE-NANCE
page 3-20
GO TO LOCAL
page 3-11
• Local Data: Opens the Main Menu Local Data screen. See page 3-11 for more details.• Maintenance: Opens the maintenance screen. See page 3-20 for details.
STACK#1PICK-UP
LOAD POS
Infeed End
Outfeed End
Stack #1
STACK#2PICK-UP
LOAD POS
Infeed End
Outfeed End
Stack #2
3-10 Alliance Series
Touch Screen
Main Menu LOCAL
MAINTE-NANCE
page 3-20
GO TO REMOTEpage 3-11
FLIP ROT:ONRDY READY
OK TO FEED-OUT
123.45
NO ACCESSI-14
LOAD POS
LONG[>96”]
PICK-UP
LOAD POS
PICK-UP
LONGSTACK
#1STACK
#2
READYENTRY
TRANSFER#1 -> #2
FLIPOFF
ROT:OFF
DOOR WIDTH
PRESET EDIT
Door WidthEntry
Running Data
Lift: Move andMode Control
Navigation
Feed ModeControl
17.2524.0036.0048.00
DoorWidth
DATA
SLOW JOGFORWARD
JOGREVERSE
AUTOFEED
FEEDTHRU
MANUALFEED
The Main Menu LOCAL screen allows direct control of the machine from the operator’s station.
Running Data:
FLIP ROT:ONRDY READY123.45 LONG
DoorWidth
DoorLength
Door ManipulationParameters
Door StackStatus
This portion of the display show door data for the door currently being processed.
Alliance Series - ON-2010 3-11
Door Width Entry:
LONG[>96”]
READYENTRY
FLIPOFF
ROT:OFF
DOOR WIDTH
PRESET EDIT
17.2524.0036.0048.00
DoorWidth
DATA
FLIPON
ROT:OFF
Door Width Select:Steps through the four Door Width Presets
Doo
r Len
gth
DoorWidth
Doo
r
Door Length Select Toggles between:
for doors longer than 96”.
For doors 96” or shorter.
LONG[>96”]
SHORT<=96”
Door Manipulation Parameters:
Sets the door’s orientation parameters. For more information see “Door Manip-ulation Parameters:” on page 3-12
Door Width Preset Edit:
Allows editing of door width preset val-ues. For more information see “Door Width Preset Edit:” on page 3-13
• Door Manipulation Parameters: The Door Manipulation indicators, Flip and Rotate, indicate how the machine will orient the door before the door leaves the machine. The four possible states are shown below.
Flip OFF, Rotate OFF:
No manipulation.
FLIP
LatchSide
HingeSide
Top
Bottom
ROT
Flip ON, Rotate OFF:
The door is flipped on it’s long axis.
FLIP
LatchSide
HingeSide
Top
Bottom
LatchSide
HingeSide
Top
BottomBefore Flip After Flip
ROT
Flip OFF, Rotate ON:
The door is rotated on it’s short axis.
LatchSide
HingeSide
Top
Bottom
LatchSide
HingeSide
Top
BottomBefore Rotate After Rotate
ROTFLIP
Flip ON, Rotate ON:
The door is flipped on it’s long axis, rotated on it’s short axis.
LatchSide
HingeSide
Top
BottomBefore Flip & Rotate After Flip & Rotate
LatchSide
HingeSide
Top
Bottom
FLIP ROT
3-12 Alliance Series
Touch Screen
• Door Width Preset Edit: Door width Preset
Edit40.25
SAVE & EXIT
PREVIOUS MENU
7 8 9
4 5 6
1 2 3
0 DEC(.)
FRC(/)
CLR
ENTERDW1-mode
DOOR-WIDTH17.2524.0036.0048.00
DOOR-WIDTH-1DW-1DW-2DW-3DW-4
17.2524.0036.0048.00
PRESET NEW
MAX. DOOR-WIDTH = XX.XX
The Door Width Preset Edit button Calls the Door Width Edit screen shown below. Use this screen to modify the door four width presets.
How to change a door width preset:
1.Use the Door Width Preset selector button to scroll to the desired preset.
DOOR-WIDTH-1DW-1DW-2DW-3DW-4
2.Use the Key Pad to enter the new door width preset value. The keyed in value will appear in the Key Pad Display. Fractional values can be entered as decimal number or fractions (see page 3-14). The value entered must be less than the Max. DOOR-WIDTH value displayed to the right of the key pad.Note: To clear a value press the CLR (clear) button.
40.25
7 8 9
4 5 6
1 2 3
0 DEC(.)
FRC(/)
DOOR-WIDTH
CLRKey Pad
Key PadDisplay
ClearButton
3.After the new value has been keyed in press the Enter key. This will load the keyed value into the “New” section of the display.
ENTERDW1-mode 40.25
7 8 9
DOOR-WIDTH40.2524.0036.0048.00
NEW
4.Save or discard changes: 17.2524.0036.0048.00
PRESET
PREVIOUS MENU
Exit with
40.2524.0036.0048.00
DW-1DW-2DW-3DW-4
NEW
SAVE & EXITExit and
no Change Save New values
• Save and Exit will save the values displayed in the “New” section of the display as door width preset values.
• Previous Menu will exit leaving the “Preset” values as door width preset values.
Alliance Series - ON-2010 3-13
Entering Fractional Values:
For decimal mode enter the number using the Decimal Point key.
For fractional input enter the whole number then press the Fraction Key.
The Fractional Key displays the screen shown to the right. When a Fractional key is pressed the value is displayed is shown in thirty seconds of an inch. For example if 1/4 is pressed, 08/32 will be displayed.When the correct value has been entered press previous menu to return to the previous screen.
Lift: Move and Mode
LOAD POS
PICK-UP
LOAD POS
PICK-UP
STACK#1
STACK#2
TRANSFER#1 -> #2
Control
Stack Control:
Holding this button will raise Stack One’s Door
Lift.
Holding this button will lower Stack One’s Door Lift.
DEC(.)
FRC(/)
[11/32] 42.34375
1/32 1/16 3/32 1/8 5/32 3/16 7/32 1/4
9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2
17/32 9/16 19/32 5/8 21/32 11/16 23/32 3/4
25/32 13/16 27/32 7/8 29/32 15/16 31/32
42
PREVIOUS MENU
Whole Number Fractional Number
STACK#1PICK-UP
LOAD POS
Infeed End
Outfeed End
Stack #1
3-14 Alliance Series
Touch Screen
Holding this button will raise Stack Two’s Door
Lift.
Holding this button will lower Stack Two’s Door Lift.
• Stack Select buttons:
Use this button to select doors from Stack #1.
Use this button to select doors from Stack #2.
• Transfer #1 -> #2: TRANSFER#1 -> #2
TRANSFER#1 -> #2
The Transfer button determines the product flow path. With Transfer OFF the doors flow out to the next machine.
Load DoorsHere
Load DoorsHere
HereLoad Doors
To Next Machine To Next Machine
TRANSFER#1 -> #2
STACK#2PICK-UP
LOAD POS
Infeed End
Outfeed End
Stack #2
STACK#1
STACK#2
Infeed End
Outfeed End
Stack #2Stack #1
Alliance Series - ON-2010 3-15
With Transfer ON the doors flow from Stack #1 to Stack #2. Typically this mode is used in con-junction with the Door manipulation (see page 3-12) to reorient doors within a stack.
Remove Doors Here
Load Doors
Stack #1
Stack #2
TRANSFER#1 -> #2
Feed Mode
• Manual Feed: Puts the feed system in manual mode. In the manual mode the feed system is con-trolled by the Manual Feed buttons described below.
• Auto Feed: Puts the feed system in Automatic mode. In this mode the feed system is controlled by the machine’s computer.
• Feed through: In this mode the door will move through the machine without being processed.
Navigation
• Remote Data: Opens the Remote Data screen. See page 3-7 for more information.• Maintenance: Opens the Maintenance screen. See page 3-20 for more information
Ready Enter Data
READYENTRYDATA
Press this button to start the process after the door data, and the door have been entered into the machine.
3-16 Alliance Series
Touch Screen
How to Run a Door in Manual Local Mode:
1.Load the door or doors into the machine.2.Select the Stack
STACK#1
STACK#2
3.Raise the stack to clamping height.
PICK-UP
4.Enter the door data.
LONG[>96”]
FLIPON
ROT:OFF
DoorWidth
5.Select the ModeTRANSFER
#1 -> #2
6.READYENTRYDATA
Press Ready Enter-Data to start the process.
Alliance Series - ON-2010 3-17
Manual Mode
123.45
PREVIOUS MENU
MANUALFEED
FORKLIFT
FEED MODE
JOGREV
CARRIAGE
MANUAL FEED
123.45
AUTOFEED UNCLAMP
SLOW JOGFWD
UP
DOWN
#2#1
LIFT #1 LIFT #2
PositionIndicators
DOWN
UP
DOWN
UP
DOWN
RESETSEQUENCE
This screen give manual control to the operator.
Reset Sequence:
Use this button to return the ON-2010 back to a known state after any manual move.
Forklift Control:
Holding this button will move the Forklift up.
Holding this button will move the Forklift down.
Carriage Control:
Holding this button will move the Carriage and Vacuum Clamp toward stack 1.
Holding this button will move the Carriage and Vacuum Clamp toward stack 2.
RESETSEQUENCE
UP
DOWN
#1
#2
Infeed End
Outfeed End
Stack #1 Stack #2
3-18 Alliance Series
Touch Screen
Stack Control:
Holding this button will raise Stack One’s Door Lift.
Holding this button will lower Stack One’s Door Lift.
Holding this button will raise Stack Two’s Door
Holding this button will lower Stack Two’s Door Lift.
• CLAMP UNCLAMP : This button has two states, Clamp (Red) and Un-Clamp (Green).
When the button is Green the vacuum is applied to the Vacuum Clamp. When the button is Red, the Vacuum is removed from the Vacuum clamp.
Feed Mode:
• Manual Feed: Puts the feed system in manual mode. In the manual mode the feed system is con-trolled by the Manual Feed buttons described below.
• Auto Feed: Puts the feed system in Automatic mode. In this mode the feed system is controlled by the machine’s computer.
STACK#1LIFT
UP
DOWN
Infeed End
Outfeed End
Stack #1
STACK#2LIFT
UP
DOWN
Infeed End
Outfeed End
Stack #2
Alliance Series - ON-2010 3-19
Maintenance -1
PREVIOUS MENU
page 3-11
123.45
FORKLIFTCHANGE
124
130
123.45
MANUAL FEED
JOGREVERSE SLOW JOG
FORWARD
NEXT PAGE
page 3-21
MANUAL MODE
page 3-18
MODBUSMODE
PLC Port-1MODE
172-SCN1_1v1
POSITION
CARRIAGECHANGEPOSITION
CMD ACK
FORK
CARR
Data:
• Fork: Shows the current position of the fork.• Carriage: Shows the current servo position of the carriage.
Change Position:
• Forklift Change Position: Displays the Forklift Change Position menu. Parameters on this screen are factory set and should need no modification.
• Carriage Change Position: Displays the Carriage Change Position menu. Parameters on this screen are factory set and should need no modification.
Feed Mode
• Manual Feed: Puts the feed system in manual mode. In the manual mode the feed system is con-trolled by the Manual Feed buttons described below.
• Auto Feed: Puts the feed system in Automatic mode. In this mode the feed system is controlled by the machine’s computer.
• Feed through: In this mode the door will move through the machine without being processed.• Call Door:
Manual Feed:
• Jog Rev (Jog Reverse): Turns on the feed system in reverse mode if the Feed Mode is set to manual.• Slow: This button when pressed with either Jog Rev or Jog Fwd puts the feed system in slow mode.• Jog Fwd (Jog Forward): Turns on the feed system in reverse mode if the Feed Mode is set to man-
ual.
Navigation:
• Manual More: Opens the Manual Mode screen. See page 3-18 for more information.• Next Page: Opens the second maintenance page. See page 3-21 for more information.
3-20 Alliance Series
Touch Screen
• Previous Menu: Opens the previous page.
Maintenance -2
PREVIOUS MENU
page 3-2012
12
CONTRAST LEVEL (0 - 31)
COLOR BRIGHT-NESS (0 - 31)
PLC INPUT-OUTPUT
PLC TIMER STATUS
SCRIPT&DRIVESTATUS
PLC M_BIT STATUS
MACHINE DATApage 3-22
TECH SUPPORT page 3-22
Touch Screen view adjustments:
• Color Brightness: Adjusts the touch screen’s brightness. • Contrast Level: Adjusts the touch screen’s contrast level.
Navigation:
• PLC Input-Output: Opens a trouble shooting screen.• PLC Times Status: Opens a trouble shooting screen. • Script & Drive Status: Opens a trouble shooting screen.• PLC M_BIT Status: Opens a trouble shooting screen.• Machine Data: Opens the Machine Data Screen. See page 3-22 from more information.• Tech Support: Opens the Tech Support screen. See page 3-22 for more information.• Previous Menu: Opens the previous screen.
Alliance Series - ON-2010 3-21
Machine Data
MACHINE DATAMACHINE TOTAL
DAILY TOTAL
1,004,576
842
RESET PREVIOUS MENU
page 3-21DAILY
• Machine Total: Displays the count of completed milling cycles.• Daily Totals: Displays the total number of milling cycles completed since Reset Daily was pushed.• Reset: Resets Daily Totals to 0.• Previous Menu: Returns to the previous menu.
Technical Support
Previous Screen
page 3-21
TECHNICAL SUPPORT4:00 A.M to 4:30 P.M. (PACIFIC TIME)
MONDAY through FRIDAYPH: 800-553-5825
This screen displays KVAL’s support contact information. For more information visit www.kvalinc.com.
3-22 Alliance Series
Homing the ON-2010
Homing the ON-2010The Rail must go through a homing routing before any other operation is performed. Performing the homing routine establishes a home position - a zero-reference position from which the Rail measures its motion when making cuts.You should home the Rail:
• After powering up the system• After hitting the STOP then START buttons• When recovering from an Emergency Stop
To Home the ON-2010
1.On the touch screen Press OK to HOME.
O.K. TO HOME
Note: If there is a door in the Rail machine see step 6. under “How to Manually remove uncompleted doors from the line:” on page 1-16.
Alliance Series 3-23
3-24 Alliance Series
CHAPTER 4 Calibrating the ON-2010
Coming Soon
Alliance Series 4-1
Calibrating the ON-2010
4-2 Alliance Series
CHAPTER 5 FACE
This chapter provides operating instructions for the KVAL FACE.
Alliance Series 5-1
FACE
5-2 Alliance Series
FACE - Operator’s Tour:
FACE - Operator’s Tour:
Infeed
Outfeed
HeadRight Hand Stops
Left Hand Stops
Operator’sStation
Control
Start Machine
START
STOP
Disable AutoFeed
Reset Drives
Drills 5&6Speed Adjust
ControlTransformer
Start SequenceRouter
#1
Router#2
Router#3
Router#4
Panel
• Control Transformer: Applies electrical power to control circuits and computer.• Start Machine: Applies electrical power to drive circuits.• Start Sequence: Starts processing the door.• Drills 5&6 Speed Adjust: Speed adjust for the top and bottom function drills.• Disable Auto Feed: Turns Auto Feed off. • Reset Drives: Resets faulted motor drives.• Touch Screen: See “Touch Screen” on page 5-5 for more information.• Router #1: If lit indicates Router High Frequency Motor Drive One faulted. Press to reset.• Router #2: If lit indicates Router High Frequency Motor Drive Two faulted. Press to reset.• Router #3: If lit indicates Router High Frequency Motor Drive Three faulted. Press to reset.• Router #4: If lit indicates Router High Frequency Motor Drive Four faulted. Press to reset.
Alliance Series 5-3
Cutting Head
There are six tools available, three for the top face of the door and three for the bottom face of the door. The FACE machine will automatically chose a tool based on door face, top or bottom, and cut size. Most machines are equipped with four routers and two drills. Top Tool Numbers
Bottom Tool Numbers 4 2 6
3 1 5
Routers
Drills
Routers
5-4 Alliance Series
Touch Screen
Main Screen
CLAMP/
38-00-SCN5_1v1
S P E E DD E P T H O F C U T
F E E D M O D E
MANUAL OPERATION
AUTO
1 32 4A CB D
UNCLAMP
DRIVE FAULT
TROUBLE SHOOTING
MANUAL RUN
page 5-6
TouchScreenProgram Version
Drive Fault
OFFFEEDTHRU
Manual ModeIndicator HOMINGHOMING Homing
Indicator
Indication
• Depth of Cut: Adjusts the depth of cut per pass where A is a lesser depth and D is greater depth. Use a lesser depth of cut for harder material and a greater depth of cut for softer material.
• Speed: Sets the cutting speed where 1 is minimum and 4 is maximum. Use a slower speed for harder material and a faster speed for softer material.
• Feed Mode: Puts feed system into one of three modes:Off (Red): Feed system is in full manual control.Auto (Green): Feed system is in fully automatic mode.Feedthru (Aqua): Feed system is in fully automatic mode, but the machine will not process the door.
• Touch Screen Program Version: Indicates the touch screen’s program version. Have this number available when calling KVAL for troubleshooting assistance.
• Clamp/Unclamp: Toggles the feed system’s door clamp between clamped and unclamped.• Manual Mode Indicator: Indicates the machine is in manual operating mode.• Homing Indicator: Indicates the machine is performing the homing process.• Drive Fault Indicator: Indicates a drive fault.• Trouble Shooting: Calls the Trouble Shooting screen.• Manual Run: Calls the Manual Run screen. See “Manual Run Screen” on page 5-6 for more infor-
mation.
Face 5-5
Manual Run Screen
JOGReverse SLOW JOG
Forward
JOGOpen
DRIVE FAULT
M A N U A L F E E D
MANUAL WIDTH ADJUST
F E E D M O D E
TROUBLE SHOOTING
AUTO RUN
page 5-5
JOGClose
MANUAL
CLAMP/AUTO UNCLAMPOFFFEEDTHRU
Manual ModeIndicator
Drive FaultIndication
• Feed Mode: Puts feed system into one of three modes:Off (Red): Feed system is in full manual control.Auto (Green): Feed system is in fully automatic mode.Feedthru (Aqua): Feed system is in fully automatic mode, but the machine will not process the door.
• Clamp/Unclamp: Toggles the feed system’s door clamp between clamped and unclamped.• Manual Width Adjust:
JOG Open: Feed system will open when this button is pressed. This is a momentary button. The action will only occur when the button is pressed.JOG Closed: Feed system will close when this button is pressed. This is a momentary button. The action will only occur when the button is pressed.
• Manual Mode Indicator: Indicates the machine is in manual operating mode.• Manual Feed:
JOG Reverse: Moves the feed system in the reverse direction. This is a momentary button. The action will only occur when the button is pressed.SLOW: Puts the feed system in slow mode. Works in conjunction with JOG Reverse and JOG For-ward. This is a momentary button. The action will only occur when the button is pressed.JOG Forward: Moves the feed system in the forward direction. This is a momentary button. The action will only occur when the button is pressed.
• Drive Fault Indicator: Indicates a drive fault.• Trouble Shooting: Calls the Trouble Shooting screen.• Manual Run: Calls the Manual Run screen. See “Manual Run Screen” on page 5-6 for more infor-
mation.
5-6 Face
Homing the Face
Homing the FaceThe Face must go through a homing routing before any other operation is performed. Performing the homing routine establishes a home position - a zero-reference position from which the Face measures its motion when making cuts.You should home the Face:
• After powering up the system• After hitting the STOP then START buttons• When recovering from an Emergency Stop
To Home the Face
1. Remove any doors from the feed system.2. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button
below it to read Home.3. Click twice on the Home button. The Face should start the homing operation.
NOTE:While the homing operation is in progress, the Home button changes its label to Homing.
Alliance Series 5-7
5-8 Alliance Series
Router Collets
Router ColletsTool Insertion
Router Protrusion 1 7/8”
1.Insert tool into collet with the correct protrusion length from the collet face to the tip of the tool as shown above.
Note: The protrusion distances shown above are for standard machines. The protrusion distance can vary depending on the bit length and required cut depth. Regardless of the protrusion distance, insure there is a minimum of 1/8” clearance from the end of the bit to the bottom of the tool holder.2.Tighten the tool holder nut using the appropriate
wrenches.Note: Most machines come with a gauge to set this distance.
Collet Maintenance
Periodically remove the collet assembly and use a compressed air gun to blow out debris from both the nut and collet.Check the collet for bluing (overheating) or physical damage. If there is overheating or physical damage the collet must be replaced.
Note: When inserting the collet into nut insure collet “snaps” into the nut.
Collet
1/8” minimum
NutBit
“Snap”
Alliance Series 5-9
5-10 Alliance Series
CHAPTER 6 Calibrating the FACE
Face 6-1
Calibrating the FACE
How to modify a Parameter:1.In the KVAL 2006 interface, click once on the Maint button.2.Click the Cal button. 3.You will see a message pop up in front of the graphic display area. This is a warning message, inform-
ing you that if you proceed, it will abort any cutout progra.
4.Click on the pop-up message to proceed.Click the Cal OK? button. The Jog Menu page appears:
5.Click the Calibration button. This takes you to the calibration pages where the calibration takes place. The first page displayed is Calibration Page 1:
6.Use the Page up and Page Down buttons to navigate to the desired parameter.7.See “Parameters” on page 6-4. to find the parameter to modify. Use the following process to modify
the parameter value.a.Integrate the Modifier (if needed):
6-2 Face
How to modify a Parameter:
If the right-hand field has a value other than zero, click the left-most field to integrate the value. The result should update the left-most field. Before proceeding to the next step, verify that the right-hand field is empty or shows zero.
(Modifier field has a non-zero value)Example:(Click on the left-most field)
(Offset is updated, Modifier field is empty)
b.Type the new value in the right-hand field, press the Enter key, and then click the left-most field to register the new offset.
Note: Some parameters are protected against modification. Parameter protection is indicated by an asterisk (*) at the end of the field name. Also if an attempt is made to modify a protected parameter Combined Variables Protected message is displayed. To temporarily defeat the protection press the Protect Cal button.When you are finished making the calibration adjustments, click the Exit button. This exits the Calibra-tion page and the KVAL 2006 program.
Face 6-3
Calibrating the FACE
ParametersTool size and Cutting Depth
Top Main Router Top MainRouter
Enter the diameter of the Top Main Router bit.
Top Router Depth
Increasing this parameter will increase the depth of the Top Main Router plunge.
Bottom Main Router
Router MainBottom
Enter the diameter of the Bottom Main Router Bit.
Bottom Main Router Depth
Increasing this parameter will increase the depth of the Bot-tom Main Router plunge.
D1 Top D1 TopTool
Enter the diameter of the D1 Top router bit.
D1 Top Depth
Increasing this parameter will increase the depth of the D1 Top router plunge.
+
-Door Face
Deeper
Shallower
+
-Door Face
Deeper
Shallower
+
-Door Face
Deeper
Shallower
6-4 Face
Parameters
D1 Bottom
D1 BottomTool
Enter the diameter of the D1 Bottom router bit.
D1 Bottom Depth
Increasing this parameter will increase the depth of the D1 Bottom router plunge.
D2 Top D2 TopTool
Enter the diameter of the D2 Top drill bit.
D2 Top Depth
Increasing this parameter will increase the depth of the D2 Top drill plunge.
D2 Bottom
D2 BottomTool
Enter the diameter of the D2 Bottom drill bit.
D2 Bottom Depth
Increasing this parameter will increase the depth of the D2 Bottom drill plunge.
+
-Door Face
Deeper
Shallower
+
-Door Face
Deeper
Shallower
+
-Door Face
Deeper
Shallower
Face 6-5
Calibrating the FACE
Automated Tool Selection
D1 PegNot used.
D1 NegNot used.
D2 Neg
D1 Pos
ToolDiameter
D1 Neg
and ActualHole Size
MaximumDiameter
MinimumDiameter
This parameter sets the minimum diameter cut to use the D2 Tools. The value entered will be subtracted from the tool diameter set in the D2 Top and D2 Bottom parameters. The bit in the D2 Tool will determine the actual cut diameter.
D2 Pos
This parameter sets the minimum diameter cut to use the D2 Tools. The value entered will be added from the tool diameter set in the D2 Top and D2 Bottom parameters. The bit in the D2 Tool will determine the actual cut diameter.
D2 Tools
6-6 Face
Parameters
Cut Location
Top Main Router X
Factory set to 0. No adjustment necessary.
Top Router Y
Factory set to 0. No adjustment necessary.
Face 6-7
Calibrating the FACE
D1 X
D1 Tools
+-Cut Position
Infeed
X Axis
Sets the position of the cut referenced to the infeed end of the machine along the X axis for cuts using the D1 Tools. Increasing this parameter value will move the cut away from the infeed end of the machine. Reducing this parameter will move the cut toward the infeed end of the machine.Note: This parameter is referenced to the Top Main Router X parameter. Insure the Top Main Router X parameter is set correctly before adjusting the D1 X parameter.Since this parameter is referenced to the infeed end of the machine and not the top of the door, it will affect each hand differently. See below:
D1 Y
+-
Lock Side
Sets the position of the cut referenced to the lock side of the door for cuts using the D1 Tools. Increasing this parameter value will move the cut away from the lock side of the door. Reducing this parameter will move the cut toward the lock side of the door.Note: This parameter is referenced to the Top Main Router Y parameter. Insure the Top Main Router Y parameter is set correctly before adjusting the D1 Y parameter.
Left Hand Door
Top of Door
Right Hand Door
Top of Door
+
-
-
+
6-8 Face
Parameters
D2 X
+-Cut Position
Infeed
D2 ToolsX Axis
Sets the position of the cut referenced to the infeed end of the machine along the X axis for cuts using the D2 Tools. Increasing this parameter value will move the cut away from the infeed end of the machine. Reducing this parameter will move the cut toward the infeed end of the machine.Note: This parameter is referenced to the Top Main Router X parameter. Insure the Top Main Router X parameter is set correctly before adjusting the D2 X parameter.Since this parameter is referenced to the infeed end of the machine and not the top of the door, it will affect each hand differently. See below:
D2 Y
+-
Lock Side
Sets the position of the cut referenced to the lock side of the door for cuts using the D1 Tools. Increasing this parameter value will move the cut away from the lock side of the door. Reducing this parameter will move the cut toward the lock side of the door.Note: This parameter is referenced to the Top Main Router Y parameter. Insure the Top Main Router Y parameter is set cor-rectly before adjusting the D1 Y parameter.
Left Hand Door
Top of Door
Right Hand Door
Top of Door
+
-
-
+
Face 6-9
Calibrating the FACE
Left Hand X
+-Top ofCut
Position the Door
L e f t H a n d S t o p sAdjusts the position of a cut referenced ALL Left Hand Stops.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
Right Hand X
+-Top of Cut
Positionthe Door
R i g h t H a n d S t o p sAdjusts the position of a cut referenced ALL Right Hand Stops.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
6-10 Face
Parameters
SSX1:
Position of mid machine photo eyes. Factory set, no adjustment necessary.
SSX2:
Position of mid machine photo eyes. Factory set, no adjustment necessary.
SSX3
Not used.
SSX4
Not used.
SSX5
Not used.
Face 6-11
Calibrating the FACE
Left Stop Calibrations
Left Stop 1
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
1
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 1.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 1 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 1 calibration if it is the only cut out of calibration.
Left Stop 2
1 2 3 4 5 6 7 8 9 10 11
Left Hand Stops
1234567891011
Right Hand Stops
2
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 2.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 2 is replaced. To determine if this parameter needs cal-ibration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 2 calibration if it is the only cut out of calibration.
6-12 Face
Parameters
Left Stop 3
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
3
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 3.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 3 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 3 calibration if it is the only cut out of calibration.
Left Stop 4
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
4
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 4.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 4 is replaced. To determine if this parameter needs cal-ibration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 4 calibration if it is the only cut out of calibration.
Face 6-13
Calibrating the FACE
Left Stop 5
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
5
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 5.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 5 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 5 calibration if it is the only cut out of calibration.
Left Stop 6
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
6
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 6.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 6 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 6 calibration if it is the only cut out of calibration.
6-14 Face
Parameters
Left Stop 7
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
7
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 7.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 7 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 7 calibration if it is the only cut out of calibration.
Left Stop 8
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
8
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 8.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 8 is replaced. To determine if this parameter needs cal-ibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 8 calibration if it is the only cut out of calibration.
Face 6-15
Calibrating the FACE
Left Stop 9
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
9
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut referenced to Left Hand Stop 9.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Left Hand Stop 9 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 9 calibration if it is the only cut out of calibration.
Left Stop 10
1 2 3 4 5 6 7 8 9 10 11
Left Hand Stops
1234567891011
Right Hand Stops
10
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut refer-enced to Left Hand Stop 10.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjustment. It may need adjust-ment if the Left Hand Stop 10 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 10 calibration if it is the only cut out of calibration.
6-16 Face
Parameters
Left Stop 11
1 2 3 4 5 6 7 8 9 10 11
Left Hand Stops
1234567891011
Right Hand Stops
11
+-Top ofCut
Position the Door
Left Hand StopsAdjusts the position of a cut refer-enced to Left Hand Stop 11.
• Increasing this value will move the cut closer to the Top of the Door.
• Decreasing this parameter will move the cut farther from the Top of the Door.
• NOTE: This parameter is fac-tory set and typically will not need adjustment. It may need adjustment if the Left Hand Stop 11 is replaced. To deter-mine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Left Hand X parameter (see “Left Hand X” on page 6-10). Adjust the Left Hand Stop 11 calibration if it is the only cut out of calibration.
Face 6-17
Calibrating the FACE
Right Stop Calibrations
Right Stop 1
1 2 3 4 5 6 7 8 9 10 11
Left Hand Stops
1234567891011
Right Hand Stops
1
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 1.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 1 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 1 calibration if it is the only cut out of calibration.
Right Stop 2
1 2 3 4 5 6 7 8 9 10 11
Left Hand Stops
1234567891011
Right Hand Stops
2
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 2.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 2 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 2 calibration if it is the only cut out of calibration.
6-18 Face
Parameters
Right Stop 3
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
3
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 3.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 3 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 3 calibration if it is the only cut out of cali-bration.
Right Stop 4
1 2 3 4 5 6 7 8 9 10 11
Left Hand Stops
1234567891011
Right Hand Stops
4
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 4.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 4 is replaced. To determine if this parameter needs cali-bration, make three test cuts using three different left hand stops. If all three test cuts are out of cali-bration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 4 calibration if it is the only cut out of calibration.
Face 6-19
Calibrating the FACE
Right Stop 5
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
5
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 5.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 5 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 5 calibration if it is the only cut out of cali-bration.
Right Stop 6
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
6
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 6.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 6 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 6 calibration if it is the only cut out of cali-bration.
6-20 Face
Parameters
Right Stop 7
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
7
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 7.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 7 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 7 calibration if it is the only cut out of cali-bration.
Right Stop 8
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
8
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 8.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 8 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 8 calibration if it is the only cut out of cali-bration.
Face 6-21
Calibrating the FACE
Right Stop 9
1 2 3 4 5 6 7 8 9 1011
Left Hand Stops
1234567891011
Right Hand Stops
9
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 9.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 9 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 9 calibration if it is the only cut out of cali-bration.
Right Stop 10
1 2 3 4 5 6 7 8 9 10 11
Left Hand Stops
1234567891011
Right Hand Stops
10
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 10.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 10 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 10 calibration if it is the only cut out of cali-bration.
6-22 Face
Parameters
Right Stop 11
1 2 3 4 5 6 7 8 9 10 11
Left Hand Stops
123456789101111
+-Top of Cut Position
the Door
Right Hand StopsAdjusts the position of a cut referenced to Right Hand Stop 11.
• Increasing this value will move the cut farther from the Top of the Door.
• Decreasing this parameter will move the cut closer to the Top of the Door.
• NOTE: This parameter is factory set and typically will not need adjust-ment. It may need adjustment if the Right Hand Stop 11 is replaced. To determine if this parameter needs calibration, make three test cuts using three different left hand stops. If all three test cuts are out of calibration then adjust the Right Hand X parameter (see “Right Hand X” on page 6-10). Adjust the Right Hand Stop 11 calibration if it is the only cut out of cali-bration.
•
Face 6-23
Calibrating the FACE
6-24 Face
CHAPTER 7 Architect DI-DM
This chapter provides operating instructions for the KVAL Architect DI-DM.
Alliance Series 7-1
Architect DI-DM
7-2 Alliance Series
Architect DI-DM - Operator’s Tour
Architect DI-DM - Operator’s Tour
Feed Direction
Infeed End
Outfeed End
BackSection
FrontSection
Operator’sStation
ElectricalCabinets
HeadOne
HeadTwo
HeadThree
HeadFour
Control Panel:
Machine
START
STOP
Deep MortiseBlow OFF
ControlTransformer
Start Sequence
OFF ONTouch Screen
• Control Transformer: Applies electrical power to control circuits and computer.• Machine: Applies electrical power to drive circuits.• Start Sequence: Starts processing the door.• Deep Mortise Blow OFF: Turns the Deep Mortise blow off ON or OFF. • Touch Screen: See “Touch Screen” on page 7-4 for more information.
Alliance Series 7-3
Touch ScreenMain Screen
MANUAL RUN
page 7-5
MACHINE DATA
page 7-6
TROUBLE SHOOTING
Feed Select
• Off: Feed system stops.• Auto Feed: Doors will enter the machine, be processed and sent out with no operator intervention.• Feed Thru: Doors will pass through the machine without being processed.
Back Section Speed
• This sets the cutting speed of the backsection. Pressing this button will increment the speed range. Range values are from 1 to 4. If the indicator is on range 4 and the range button is pressed the speed range will drop back to 1.
Hinge Speed
• This sets the cutting speed of the front section. Pressing this button will increment the speed range. Range values are from 1 to 4. If the indicator is on range 4 and the range button is pressed the speed range will drop back to 1.
Navigation
• Trouble Shooting: Opens the Trouble Shooting screen.• Machine Data: Opens the Machine Data screen. See “Machine Data Screen” on page 7-6.• Manual Run: Opens the Manual Run screen. See “Manual Run Screen” on page 7-5.
7-4 Alliance Series
Touch Screen
Manual Run Screen
TROUBLE SHOOTING
MAIN MENU
page 7-4
• Start Sequence: Starts the milling process.• Stop Up/Down: Toggles the door stops up or down.• Clamp Unclamp: Toggles the clamp clamped or unclamped.
Manual Feed
• Jog Reverse: Moves the feed in the reverse direction.• Fast: Pressing this button in conjunction with Jog Reverse or Jog Forward puts the feed in fast
mode. • Jog Forward: Moves the feed in the forward direction.
Navigation
• Trouble Shooting: Opens the trouble shooting menu.• Main Menu: Opens the Main menu. See “Main Screen” on page 7-4.
Alliance Series 7-5
Machine Data Screen
• Total Count: Displays the count of completed milling cycles.• Total Running Hours: Displays the total running time in hours of the machine.• Daily Count: Displays the total number of milling cycles completed since Daily Reset was pushed.• Daily Running Hours Mins: Displays the total running time of the machine since Daily Reset was
pushed.• Reset Daily: Resets both Daily Count and Daily Running Hours Mins to 0.• Previous Menu: Returns to the previous menu.
7-6 Alliance Series
Homing the Architect DI DM
Homing the Architect DI DMThe Architect DI DM must go through a homing routing before any other operation is performed. Per-forming the homing routine establishes a home position - a zero-reference position from which the Architect DI DM measures its motion when making cuts.You should home the Architect DI DM:
• After powering up the system• After hitting the STOP then START buttons• When recovering from an Emergency Stop
To Home the Architect DI DM
1.Maint
Home
OKHome?
Homing
In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.
2. Click the Home button. This will change the button label to OK to Home?3.CLick the OK to Home? button.4.NOTE:While the homing operation is in progress, the Home button changes its label to Homing.
Alliance Series 7-7
7-8 Alliance Series
Router Collets
Router ColletsTool Insertion
Router Protrusion Front Hinge Router 2”Back Section Routers 5 3/4”
1.Insert tool into collet with the correct protrusion length from the collet face to the tip of the tool as shown above.
Note: The protrusion distances shown above are for standard machines. The protrusion distance can vary depending on the bit length and required cut depth. Regardless of the protrusion distance, insure there is a minimum of 1/8” clearance from the end of the bit to the bottom of the tool holder.2.Tighten the tool holder nut using the appropriate
wrenches.Note: Most machines come with a gauge to set this distance.
Collet Maintenance
Periodically remove the collet assembly and use a compressed air gun to blow out debris from both the nut and collet.Check the collet for bluing (overheating) or physical damage. If there is overheating or physical damage the collet must be replaced.
Note: When inserting the collet into nut insure collet “snaps” into the nut.
Collet
1/8” minimum
NutBit
“Snap”
Alliance Series 7-9
7-10 Alliance Series
CHAPTER 8 Calibrating the Architect DI-DM
Architect DI DM 8-1
Calibrating the Architect DI-DM
How to modify a Parameter:1.In the KVAL 2006 interface, click once on the Maint button.2.Click the Cal button. 3.You will see a message pop up in front of the graphic display area. This is a warning message, inform-
ing you that if you proceed, it will abort any cutout progra.
4.Click on the pop-up message to proceed.Click the Cal OK? button. The Jog Menu page appears:
5.Click the Calibration button. This takes you to the calibration pages where the calibration takes place. The first page displayed is Calibration Page 1:
6.Use the Page up and Page Down buttons to navigate to the desired parameter.7.See “Parameters” on page 8-4. to find the parameter to modify. Use the following process to modify
the parameter value.a.Integrate the Modifier (if needed):
8-2 Architect DI DM
How to modify a Parameter:
If the right-hand field has a value other than zero, click the left-most field to integrate the value. The result should update the left-most field. Before proceeding to the next step, verify that the right-hand field is empty or shows zero.
(Modifier field has a non-zero value)Example:(Click on the left-most field)
(Offset is updated, Modifier field is empty)
b.Type the new value in the right-hand field, press the Enter key, and then click the left-most field to register the new offset.
Note: Some parameters are protected against modification. Parameter protection is indicated by an asterisk (*) at the end of the field name. Also if an attempt is made to modify a protected parameter Combined Variables Protected message is displayed. To temporarily defeat the protection press the Protect Cal button.When you are finished making the calibration adjustments, click the Exit button. This exits the Calibra-tion page and the KVAL 2006 program.
Architect DI DM 8-3
Calibrating the Architect DI-DM
ParametersFront Section
Pocket Definitions
Feed Direction
Predrill cuts
Chisel cuts
Hinge Pocket
Door
Hinge LocationsHinge 1 Hinge 2 Hinge 3 Hinge 4
Infeed Outfeed
Full Front section Calibration Procedure
1.Set Hinge Backset.2.Set Predrill Vert.3.Set Hn Vert. (n = hinge number)4.Set Hn Horiz. (n = hinge number)
8-4 Architect DI DM
Parameters
Pocket Parameters - Predrills
Feed Direction
Notes:• Increasing the parameter value will move element in the
direction of parameter arrow.
Predrill n Vert
n = Hinge number
Pocket Parameters - General
Hn 3deg Vert (Set Hn Vert Offset first) Hn Vert Offset
Hn Left Side (Note: Predrill holes remain stationary)
Hn X Offset Chisel LL Hn X Offset Chisel LR
Hn Y Offset to Chisel LL Hn Y Offset to Chisel LR
Hn LH X Offset (For Left Hand mode)Hn RH X Offset (For Right hand mode)
Feed Direction
n = Hinge number
Notes:• Increasing the parameter value will move element in the
direction of parameter arrow.• All parameters are for both left and right hand unless noted.
Architect DI DM 8-5
Calibrating the Architect DI-DM
Router Diameter
Hn Router Diam
Notes: • The router diameter is normally set to the diameter of router bit. • Increasing this value decreases the size of the hinge pockets.
Hn = Hinge Number
General Front Section:
HINGE Z Each Pass
Increasing this parameter will increase the depth of cut for each pass of the hinge router plunge.
Hinge Outfeed Stop
Increasing this parameter will move all hinge locations away from the infeed stop (For left hand or right hand reverse modes).
Hinge Infeed Stop:
Increasing this parameter will move all hinge locations away from the infeed stop (For right hand mode only).
8-6 Architect DI DM
Back Section
Back SectionRouter
Router Horizontal, Vertical
Notes:• Increasing the parameter value will move element in the
direction of parameter arrow.
3deg Vert (Set Vert Offset first)
Feed Direction
*Set front section hinge locations before
Vert Offset
Lock Location RH (For Right Hand mode)*Lock Location LH (For Left hand mode)*
setting these parameters.
Router Diameter
Router Diam
Increasing the Router Diam value decreases the size of the Face plate pockets.
Architect DI DM 8-7
Calibrating the Architect DI-DM
Router Depth
Increasing this parameter will increase the depth of the router plunge.
3 Deg Depth
Increasing this parameter will increase the depth of the router plunge in 3 degree mode.NOTE: Calibrate Router depth first.
Z Each Pass:
Increasing this parameter will increase the depth of cut for each pass of the router plunge.
Chisels
Note: Increasing the parameter value will move the element in the direction off the parameter arrow.
X Offset to Chisel UL
Y Offset to Chisel UL
Y Offset to Chisel LL
X Offset to Chisel LL
Y Offset to Chisel LR
X Offset to Chisel LR
X Offset to Chisel UR
Y Offset to chisel UR
Z Offset to Chisel aa
Increasing this parameter will increase the depth of the chisel (aa = chisel location UL, LL, UR, LR).
8-8 Architect DI DM
Back Section
Deep Mortis
Notes:• Increasing the parameter value will move element in the
direction of parameter arrow.
Feed Direction
DM Vertical (Set Router Vert
Deep Mortis X
Offset and 3deg. Vert before adjusting this parameter)
DM Diameter
Feed DirectionNotes:
• Increasing the DM Diameter value decreases the size of the deep mortise pocket.
• For a faster cut increase the router bit size. If the bit diameter is the same size as the cut, the router will make the cut in one pass.
• A smaller router bit will result in a squarer hole
DM Diameter
Z Ech DM Pass:
Increasing this parameter will increase the depth of cut for each pass of the deep mortis plunge.
DM Depth:
Increasing this parameter will increase the depth of the deep mortis plunge.
Architect DI DM 8-9
Calibrating the Architect DI-DM
Counter Rotating Router
Notes:• Increasing the parameter value will move element in the
direction of parameter arrow.• If x or y get out of adjustment, making it cut too deep on Z
is a good way to “find” the cut and get it calibrated relative to the main router bit.
Feed Direction
Cnt Rout Vert (Set Router Vert
Cnt Rout Horiz X
Offset and 3deg. Vert before adjusting this parameter)
Cnt Rout Diam (Counter Router Diameter)
Notes: Increasing the Cnt Rout Diam value decreases the size of the Counter Rotating
Cnt Rout Depth:
Increasing this parameter will increase the depth of the Counter Rotating Router plunge.
8-10 Architect DI DM
Back Section
Side Drills
Notes:• Increasing the parameter value will move element in the
direction of parameter arrow.
Side Drill Y (Set Router VertOffset and 3deg. Vert before
Feed Direction
Side Drill X
adjusting this parameter)
Side Drill Z:
Increasing this parameter will increase the depth of the Side Drill plunge.
Side Drill Diam:
Enter the diameter of the side drill bit.
Note: If program calls for a side drill hole size larger than the bit, the machine will use the main router bit, typically.500” diameter to cut the hole.
Architect DI DM 8-11
Calibrating the Architect DI-DM
General Back SectionSide Enc. 0
Side Enc. 0 determines the position of 0 for the width adjust system. There is no mechanical stop for this position so we must relay on the machine’s Side Encoder position to determine 0 width position. Calibration requires a square door with a known width.
1.Select 0º mode.2.Click on orange field until heading reads Side Encoder.
3.Load a perfectly square door as described below with a know width.4.Manually open and close the width adjust and record the value of the Side Encoder.5.Repeat step two 5 times.6.If the value found in step 4 is between +0.02 and -0.02 calibration is complete.7.Find the largest offset in step 4 and divide by 2.8.Change the sign of value found in step 6.9.Add the value calculated in step 6 to the existing Side Enc. 0.10.Go back to step 3.
Example:Five values: -0.015, -0.023, 0.005, -0.027, 0.015Find largest offset: -0.015, -0.023, 0.005, -0.027, 0.015Divide largest offset by 2: -0.027/2= -0.0135Change the sign -0.0135 becomes 0.0135Add 0.0135 to the existing Side Enc 0 value.
0 Position
8-12 Architect DI DM
General Back Section
Side Enc. 3DEG
Side Enc. 0 determines the position of 0 for the width adjust system. There is no mechanical stop for this position so we must relay on the machine’s Side Encoder position to determine 0 width position. Calibration requires a square door with a known width.
1.Select 3º mode.2.Click on orange field until heading reads Side Encoder.
3.Load a perfectly square door as described below with a know width.4.Manually open and close the width adjust and record the value of the Side Encoder.5.Repeat step two 5 times.6.If the value found in step 4 is between +0.02 and -0.02 calibration is complete.7.Find the largest offset in step 4 and divide by 2.8.Change the sign of value found in step 6.9.Add the value calculated in step 6 to the existing Side Enc. 3DEG.10.Go back to step 3.
Example:Five values: -0.015, -0.023, 0.005, -0.027, 0.015Find largest offset: -0.015, -0.023, 0.005, -0.027, 0.015Divide largest offset by 2: -0.027/2= -0.0135Change the sign -0.0135 becomes 0.0135Add 0.0135 to the existing Side Enc. 3DEG value.
0 Position
Architect DI DM 8-13
Calibrating the Architect DI-DM
How to select a perfectly square door (or one that’s close enough)
To determine if a door is square, measure the distance between opposite corners. If the difference between the two measurements is less than 1/16”, the door is square.
A B
Square door = ∆(AB)<1/16”
8-14 Architect DI DM
Feed System
Feed SystemInfeed RH End check:
This parameter calibrates the Right Hand End Check Sensor. This sensor is located on the backsection side of the machine directly across from the infeed stop and is used to check the door for square. The calibration procedure is described below.
1.Click on orange field until heading reads Infeed Encoder.
2.Load a perfectly square door as described above. 3.Record the value of the Infeed Encoder.4.If the value found in step 4 is between +0.02 and -0.02 Infeed RH End Check calibration is complete.5.Change the sign of value found in step 3.6.Add the value found in step 5 to the existing Infeed RH End Check value.7.Go back to step 3.
Right Hand End CheckSensor Position
Architect DI DM 8-15
Calibrating the Architect DI-DM
Outfeed LH End check:
This parameter calibrates the Left Hand End Check Sensor. This sensor is located on the backsection side of the machine directly across from the infeed stop and is used to check the door for square. The calibration procedure is described below.
1.Click on orange field until heading reads Outfeed Encoder.
2.Load a perfectly square door as described above. 3.Record the value of the Outfeed Encoder.4.If the value found in step 4 is between +0.02 and -0.02 Outfeed LH End Check calibration is com-
plete.5.Change the sign of value found in step 3.6.Add the value found in step 5 to the existing Outfeed LH End Check value.7.Go back to step 3.
Infeed Stop:
This sets the location of the Infeed stop. This parameter should always be set to 0.
Left Hand End CheckSensor Position
8-16 Architect DI DM
CHAPTER 9 EDGE
This chapter provides operating instructions for the KVAL Edge.
Alliance Series 9-1
EDGE
9-2 Alliance Series
EDGE - Operator’s Tour
Infeed
Outfeed
Operator’sStation
CuttingHead
Feed Direction
Alliance Series 9-3
Control Transformer(Maintained)
PushOff
PullOn
MACHINE
START
STOP
Mortise DepthOf Cut
1.01.5 2.0
2.5
Speed Select
70%80% 90%
100%
Auto Feed Router Depthof Cut
OffAuto
FeedThru 1.0
1.5 2.02.5
FORWARD
REVERSE
Feed DEEP MORTISE
Disable Auto Feed Disable Width Adj(Maintained)(Maintained)
PushOff
PullOn
PushOff
PullOn
BLOW OFF
OFF ON
Faster
Control Panel One
• Control Transformer: Applies electrical power to con-trol circuits and computer.
• Machine START STOP: Applies electrical power to drive circuits.
• Mortis Depth of Cut: Sets the depth of cut for each deep mortis cutting pass.
• Speed Select: Sets the cutting speed. Use higher set-tings for soft material, slower settings for hard material. If the speed ranges are not adequate for you needs please contact KVAL service.
• Auto Feed: Off Feed in manual mode. To move a door
use the Feed FWD and REV buttons.
Auto The machine will call, load and clamp a door in preparation for processing.
Feed Thru The door will be passed to the next machine without processing.
• Router Depth: Sets the depth of cut for each router pass.
• Feed: FWD Manually jogs the feed forward moving
the door toward the outfeed end of the machine.
REV Manually jogs the feed reverse moving the door toward the infeed end of the machine.
• Deep Mortise Blow Off: Turns the Deep Mortise blow off ON or OFF.• Disable Auto Feed: Stops all feed movement.• Disable Width Adjust: Stops all width adjust movement.
9-4 Alliance Series
Control Panel Two
Start Sequence
Door Clamp
Door Stop
Reset Drives
• Start Sequence: Manually starts door processing. • Door Clamp: Manually starts the door clamping process.• Door Stop: Manually extends the proper door stop. The door stop
is determined by door hand and door size.• Reset Drives: Resets the motor drives.
Alliance Series 9-5
9-6 Alliance Series
Homing the EDGE
Homing the EDGEThe EDGE must go through a homing routing before any other operation is performed. Performing the homing routine establishes a home position - a zero-reference position from which the EDGE measures its motion when making cuts.You should home the EDGE:
• After powering up the system• After hitting the STOP then START buttons• When recovering from an Emergency Stop
To Home the EDGE
1. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.
2. Click twice on the Home button. The Edge Patriot should start the homing operation. NOTE:While the homing operation is in progress, the Home button changes its label to Homing.
Alliance Series 9-7
9-8 Alliance Series
Deep Mortise Collet
Deep Mortise ColletTool Insertion
1.Insert tool into collet with 5 3/4” from the collet face to the tip of the tool. 2.Tighten the tool holder nut using the appropriate
wrenches.5 3/4”
NOTE: Insure there is a minimum of 1/8” clearance from the end of the bit to the bottom of the tool holder.
Collet Maintenance
Periodically remove the collet assembly and use a compressed air gun to blow out debris from both the nut and collet.
Check the collet for bluing (overheating) or physical damage. If there is overheating or physical damage the collet must be replaced.
Note: When inserting the collet into nut insure collet “snaps” into the nut.
Collet
1/8” minimumNut
Bit
“Snap”
Alliance Series 9-9
9-10 Alliance Series
CHAPTER 10 Calibrating the EDGE
Edge Patriot & Edge STS 10-1
Calibrating the EDGE
How to modify a Parameter:1.In the KVAL 2006 interface, click once on the Maint button.2.Click the Cal button. 3.You will see a message pop up in front of the graphic display area. This is a warning message, inform-
ing you that if you proceed, it will abort any cutout progra.
4.Click on the pop-up message to proceed.Click the Cal OK? button. The Jog Menu page appears:
5.Click the Calibration button. This takes you to the calibration pages where the calibration takes place. The first page displayed is Calibration Page 1:
6.Use the Page up and Page Down buttons to navigate to the desired parameter.7.See “Parameters” on page 10-4. to find the parameter to modify. Use the following process to modify
the parameter value.a.Integrate the Modifier (if needed):
10-2 Edge Patriot & Edge STS
How to modify a Parameter:
If the right-hand field has a value other than zero, click the left-most field to integrate the value. The result should update the left-most field. Before proceeding to the next step, verify that the right-hand field is empty or shows zero.
(Modifier field has a non-zero value)Example:(Click on the left-most field)
(Offset is updated, Modifier field is empty)
b.Type the new value in the right-hand field, press the Enter key, and then click the left-most field to register the new offset.
Note: Some parameters are protected against modification. Parameter protection is indicated by an asterisk (*) at the end of the field name. Also if an attempt is made to modify a protected parameter Combined Variables Protected message is displayed. To temporarily defeat the protection press the Protect Cal button.When you are finished making the calibration adjustments, click the Exit button. This exits the Calibra-tion page and the KVAL 2006 program.
Edge Patriot & Edge STS 10-3
Calibrating the EDGE
ParametersLock Location
Lock Location RH
Lef
t
Lef
t
Mid
dle
Rig
ht
Rig
ht
Out
boar
d
Out
boar
d
The Lock Location RH parameter sets the position of the Face Plate cut in relation to Right Stop. This stop is used when making cuts between 0” and 9’ 6” from the top of a right hand door on the hinge side. Or when making cuts between 0” and 9’ 6” from the top of a left hand door on the lock side.
- +Lock Location RH
9’ 6”
Loch Location LH
- +Lock Location LH
Lef
t
Lef
t
Mid
dle
Rig
ht
Rig
ht
Out
boar
d
Out
boar
d
The Lock Location LH parameter sets the position of the Face Plate cut in relation to Left Stop. This stop is used when making cuts between 0” and 9’ 6” from the top of a left hand door on the hinge side. Or when making cuts between 0” and 9’ 6” from the top of a right hand door on the lock side. Or for left hand top cuts and right hand bottom cuts.
9’ 6”
10-4 Edge Patriot & Edge STS
Parameters
Stops
Left Stop
- +Left Stop
Lef
t
Lef
t
Mid
dle
Rig
ht
Rig
ht
Out
boar
d
Out
boar
d
The Left Stop parameter sets the position of the Face Plate cut in relation to Left Stop. This stop is used when making cuts between 0” and 9’ 6” from the top of a left hand door on the hinge side. Or when making cuts between 0” and 9’ 6” from the top of a right hand door on the lock side. Or for left hand top cuts and right hand bottom cuts.
CAUTION: This calibration parameter is factory set to 0. Any adjustment to this parameter will affect all other calibration parameters.
9’ 6”
Middle Stop
Lef
t
Lef
t
Mid
dle
Rig
ht
Rig
ht
Out
boar
d
Out
boar
d
The Middle Stop parameter sets the position of the Face Plate cut in relation to Middle Stop. This stop is used for left hand bottom cuts and right hand top cuts.
- +Middle Stop
Edge Patriot & Edge STS 10-5
Calibrating the EDGE
Right Stop
Lef
t
Lef
t
Mid
dle
Rig
ht
Rig
ht
Out
boar
d
Out
boar
d
The Right Stop parameter sets the position of the Face Plate cut in relation to Right Stop. This stop is used when making cuts between 0” and 9’ 6” from the top of a right hand door on the hinge side. Or when making cuts between 0” and 9’ 6” from the top of a left hand door on the lock side.
- +Right Stop
9’ 6”
Left Outboard Stop
- +Left Outboard Stop
Lef
t
Lef
t
Mid
dle
Rig
ht
Rig
ht
Out
boar
d
Out
boar
d
The Left Outboard Stop parameter sets the position of the Face Plate cut in relation to Left Outboard Stop. This stop is used when making cuts on the hinge side of a left hand door greater than 9’6” tall. Or when making cuts on the lock side of a right hand door greater than 9’ 6” tall.
9’ 6”
10-6 Edge Patriot & Edge STS
Parameters
Right Outboard Stop
- +Right Outboard Stop
Lef
t
Lef
t
Mid
dle
Rig
ht
Rig
ht
Out
boar
d
Out
boar
d
The Right Outboard Stop parameter sets the position of the Face Plate cut in relation to Right Outboard Stop. This stop is used when making cuts on the hinge side of a right hand door greater than 9’6” tall. Or when making cuts on the lock side of a left hand door.
Note: The Right Outboard Stop parameter is referenced to Right Stop. Any changes to the Right Stop parameter will affect the Right Outboard Stop.
9’ 6”
Deep mortise
DM Vertical
Notes: Increasing the parameter value will move element in the direction of parameter arrow, toward the upward face of the door.
DM Vertical
Edge Patriot & Edge STS 10-7
Calibrating the EDGE
DM Diameter
Notes: Increasing the DM Diameter value decreases the size of the deep mortise pocket.
DM Diameter
Deep Mortise X:
Notes: Increasing the parameter value will move the deep mortise cut element in the direction of arrow shown above.
Deep Mortise X
Depth parameters
DM Depth: Increasing this parameter will increase the depth of the deep mortise plunge.Z Ech DM Pass: Increasing this parameter will increase the depth of cut for each pass of the deep mor-tise plunge.NOTE: Z Ech DM Pass is factory set to 0.1 inch any adjustment to this parameter may cause difficulty with some cuts.
10-8 Edge Patriot & Edge STS
Parameters
Plate Router
Router Vert Offset (Vertical Offset)
Notes: Increasing the parameter value will move element in the direction of parameter arrow.
3deg Vert (Set Vert Offset first) Vert Offset
Router Diam (Diameter)
Router Diam
Increasing the Router Diam value decreases the size of the Face plate pockets.
Depth parameters
Router Depth: Increasing this parameter will increase the depth of the router plunge.3 Deg Depth: Increasing this parameter will increase the depth of the router plunge in 3 degree mode.Z Each Pass: Increasing this parameter will increase the depth of cut for each pass of the router plunge.
Edge Patriot & Edge STS 10-9
Calibrating the EDGE
Counter Rotating Router
Cnt Rout Vert, Cnt Rout Horiz (Vertical, Horizontal)
Notes: Increasing the parameter value will move element in the direction of parameter arrow.
Cnt Rout Vert (Set Router Vert
Cnt Rout Horiz X
Offset and 3deg. Vert before adjusting this parameter)
Cnt Rout Diam (Counter Router Diameter)
Notes: Increasing the Cnt Rout Diam value decreases the size of the Counter Rotating Router pocket.
Depth parameterCnt Rout Depth: Increasing this parameter will increase the depth of the Counter Rotating Router plunge.
10-10 Edge Patriot & Edge STS
Parameters
Side Drills
Notes: Increasing the parameter value will move element in the direction of parameter arrow.
Side Drill Y (Set Router VertOffset and 3deg. Vert before
Side Drill X
adjusting this parameter)
Side Drill Z: Increasing this parameter will increase the depth of the Side Drill plunge.Side Drill Diam: Enter the diameter of the side drill bit.
Note: If program calls for a side drill hole size larger than the bit, the machine will use the Deep Mortis router to cut the hole.
Chisels
Note: Increasing the parameter value will move the element in the direction off the parameter arrow.
X Offset to Chisel UL
Y Offset to Chisel UL
Y Offset to Chisel LL
X Offset to Chisel LL
Y Offset to Chisel LR
X Offset to Chisel LR
X Offset to Chisel UR
Y Offset to chisel UR
Z Offset to Chisel aa: Increasing this parameter will increase the depth of the chisel (aa = chisel loca-tion UL, LL, UR, LR).
Edge Patriot & Edge STS 10-11
Calibrating the EDGE
Predrills
Predrill 1 X offset and Predrill 1 vert offset
Notes: Increasing the parameter value will move element in the direction of parameter arrow.
Predrill 1 X offset
Predrill 1 vert offset
Depth parameter
Predrill 1 depth: Increasing this parameter will increase the depth of the Predrill 1 plunge.
10-12 Edge Patriot & Edge STS
CHAPTER 11 DL-NCC
This chapter provides operating instructions for the KVAL Architect DLNCC.
Alliance Series 11-1
DL-NCC
11-2 Alliance Series
DLNCC - Operator’s Tour
DLNCC - Operator’s Tour
Operators Station:
Start Machine
START
STOP
Disable AutoFeed
Reset Drives Speed ControlFaster
ControlTransformer
Touch Screen
13.8765SEL RES
Cutter MotorCurrent Monitor
Power
• Control Transformer: Applies electrical power to control circuits and computer.• Start Machine: Applies electrical power to drive circuits.• Reset Drives: Resets faulted motor drives.• Speed Control: Selects cutting speed (only affects speed when the cutter is down).• Disable Auto Feed: When ON, it disables the Auto-Feed mode. Motors are still enabled for manual
control.• Cutter Motor Current Monitor: This displays the electrical current drawn by the cutter motor. This
number will vary depending on the material being cut, bit sharpness, cutting speed, motor cooling and motor wear. How to use the current monitor as a dull bit indicator:
1. During normal operation observe and record the current for several doors of each door type (steel, fiberglass, wood, particle board, etc.).
2. Once the normal current has been established for a door type, watch for the current to increase during normal operation.
3.Check the bit for wear. If the bit is still within tolerance (sharp), go back to step 2.4.If the bit is out of tolerance (dull), replace or sharpen it. Then use the last current observed to indicate
a dull bit.
Alliance Series 11-3
Touch ScreenMain Screen
MANUAL RUN
page 11-10
TOOL CHANGER page 11-8
OFF AUTO FEEDTHRU REVERSE
F E E D M O D E
S E L E C T T O O L
OSCILLATEON
EJECTOFF
RETURNTOOL
Download Received Motor Warm-upMODBUS-MODE
173-SCN1_1v1
100%
DISABLE TOOL
page 11-6
Touch ScreenProgram Version
Feed
Tool
Control
Navigation
Status Indicators
Management
ToolManagement
TOOL-4 TOOL-3 TOOL-2 TOOL-1AVAILABLE SELECTED AVAILABLE DISABLE
STEEL
FIBERGLASS
TOOL-8 TOOL-7 TOOL-6 TOOL-5DISABLE DISABLE SELECTED SELECTED
EMPTY EMPTY DRILL
FIBERGLASS FIBERGLASS FIBERGLASS
Feed OFF AUTO FEEDTHRU REVERSE
• Off: Feed system stops.• Auto: Doors will enter the machine, be processed and sent out with no operator intervention.• Feed Thru: Doors will pass through the machine without being processed.• Reverse: Momentarily reverses the feed direction as long as this button is pushed.
11-4 Alliance Series
Touch Screen
Automatic Tool Changer
The DL-NCC is equipped with an automatic tool changer. When a door file is downloaded, the DL-NCC determines if a tool change is needed, based on door material defined in the door file. If a tool change is needed, the DL-NCC follows this process to change the tool:1.Moves to the Tool Changer.2.If required, the machine scans the tool holders and records which tool holder positions are empty. This
is only done if a scan has not been done since the access gate was last opened.3.The machine moves first to the empty location where the current tool is to be returned to, and returns
the tool. After the current tool is returned, the machine moves to the location of the next tool to be used and picks it up.
4.When the tool change is complete, the DL-NCC moves to the cut start location and continues with normal operation.
If the tool changer does not detect a tool or if it encounters any other problem, then the KVAL 200* software will display an error message on the Operator’s Station monitor, indicating the problem and how to remedy the problem. If re-calibration is needed, refer to the Tool Changer calibration procedures found on page 6-37.Note: The DL-NCC retains, in memory, the tool it had at the time it was shut down. If you change the tool while the machine is off, make sure that the only empty tool slot that is not disabled is for the tool currently in the Cutter Head on the machine. For details on how to disable tool holder locations via the Touchscreen interface, refer to Disable Tool in the Tool Management section below.the
Alliance Series 11-5
Tool Tool Type
Tool Type
Tool Status
Tool Status
TOOL-4 TOOL-3 TOOL-2 TOOL-1AVAILABLE SELECTED AVAILABLE DISABLE
STEEL
FIBERGLASS
TOOL-8 TOOL-7 TOOL-6 TOOL-5DISABLE DISABLE SELECTED SELECTED
EMPTY EMPTY
Indicator
DISABLE TOOL
page 11-6
DRILL
FIBERGLASS FIBERGLASS FIBERGLASSManagement
The Select Tool portion of this screen displays information pertaining to all tools in the machine. The tool information is organized by the tools position in the tool holder starting from the pivot point out.
• Tool Type: This indicator displays the tool type information from the Calibration file in the DLNCC PC. Available tool types are: steel, fiberglass, drill and other. For more informa-tion on DLNCC calibration see “Calibration” on page 6-37
• Tool Status: These buttons show the current tool status. Pressing these buttons toggles between Selected and Avail-able:-Selected: This tool will be used for the next cut for the given tool type.-Available: This tool is available for use.-Disabled: This tool is unavailable for work. To disable a tool see below.
• Disable Tool:
CLOSEMENU
Tool-4ON
Tool-3OFF
Tool-2ON
Tool-1ON
Tool-8OFF
Tool-7OFF
Tool-6ON
Tool-5ON
DISABLE TOOLSIf all OFF, machine doesnot scan tools on Home
Opens the Disable Tool screen. Pressing the Tool buttons toggles between ON and OFF.-ON: The tool is available for use.-OFF: The tool unavailable.Note: If ALL tools are OFF, the machine will not scan tools when homing.
Example:
TOOL-4 TOOL-3 TOOL-2 TOOL-1AVAILABLE SELECTED AVAILABLE DISABLE
FIBERGLASS FIBERGLASS FIBERGLASS FIBERGLASSThe illustration to the right shows tool positions 1 through 4 have been assigned to fiberglass tooling. That tool 1 will not be used, and tool 3 is either in the cutting head, or will be selected by the cutting head before the next cut.
PivotPoint To
ol 1To
ol 2To
ol 3To
ol 4To
ol 5To
ol 6
Tool ChangerAs viewed from the
outfeed end of the machine
11-6 Alliance Series
Touch Screen
Status indicators: Download Received Motor Warm-up 100%
• Data Transfer Status: Indicates if the DL-NCC has a door file downloaded to it and is available to be run.
• Motor Warm-up: Displays the percentage (%) complete of the warm-up cycle. This reads 100% when the warm-up cycle is complete.
Control:
OSCILLATEON
EJECTOFF
RETURNTOOL
• Oscillate ON/OFF: Manually turns on/off tool oscillation. When on, the cutting tool reciprocates, increasing bit life. NOTE: The reciprocation distance is set in the calibration screen. See “A place-holder for future cross referances.” on page 6-37 for more information.
• Eject ON/OFF: Manually turns on/off the Eject function. When the Eject function is on, the cutout slug is physically knocked out with a air cylinder after the cut is complete.
• Return Tool: This function returns the tool currently in the cutting head it’s place in the tool holder. Note: It is recommended to return the tool to the tool holder at the end of each work day.
NavigationMANUAL
RUN page 11-10
TOOL CHANGER page 11-8
• Tool Changer: Opens the Tool Changer screen. See “Tool Changer” on page 11-8.• Manual Run: Opens the Manual Run screen. See “Manual Run” on page 11-10.
Alliance Series 11-7
Tool Changer
PREVIOUS MENU
page 11-4
M-2001
M2040
M-2041
M-2042
M-2043
I-41I-42I-43I-44
CR-2001:CUTTER MOTOR
CR-2040:SPEED #1
CR-2041:SPEED #2
CR-2042:SPEED #3
CR-2043:CUTTER WARMUP
CR-41: MOTOR STOPPED
CD-42: ARBOR EXTENDED
I-43: TOOL IN & RETRACTED
I-44: RETRACTED & LOCKED
TOOL CHANGER
8 7 6 5 4 3 2 1Tools Found in Holder
Current Tool In Use 1MOTOR WARM UP
Current Tool Speed 5100%
Move Cutter To Access Location
page 11-9
Start Tool Calibration page 12-1
Navigation
MotorStatus
Tool ChangerStatusMotorStatus
Motor Status
Display Description
These three signal combine to form a binary “word” sent to the motor. This binary word contains the speed selection information. A binary word decoding table is shown below:
Speed 1 Speed 2 Speed 3 Selected Speed01234567
M-2043 = Cutter in warm up mode M-2043 = Cutter not in warm up mode
I-41 = Cutter motor turning I-41 = Cutter motor not turning
I-42 = Cutter motor arbor extended I-42 = Cutter motor arbor retracted
I-43 = Tool detected and in cutter motor tool holder
I-43 = No tool detected and in cutter motor tool holder
I-44 = Tool detected and in cutter motor tool holder
I-44 = No tool detected and in cutter motor tool holder
Displays the percentage (%) complete of the warm-up cycle. This reads 100% when the warm-up cycle is complete.
M-2001 M-2001• Cutter Motor: = Cutter motor is running = Cutter motor is not running
• Speed #1:• Speed #2: • Speed #3:
• Cutter Warm-up:
• Motor Stopper:
• Arbor extended:
• Tool in & Retraced:
• Retracted & Locked:
• Motor Warm Up:
11-8 Alliance Series
Touch Screen
Tool Changer Status
• Tool Found in Holder: These indicators display the tools sensed by the cutting head calibration eye. In the example below tools tool 1, tool 3, tool 5 and tool 6 where sensed.
PivotPoint
Tool
6To
ol 5To
ol 4To
ol 3To
ol 2To
ol 1
8 7 6 5 4 3 2 1
Tool
8To
ol 7
Tool
1To
ol 2To
ol 3To
ol 4To
ol 5To
ol 6
Tool ChangerAs viewed from the
outfeed end of the machine
• Current Tool in Use: Displays the tool number currently in the cutting head.• Current Tool Speed: Displays the tool speed code entered in the calibration page. See “A place-
holder for future cross referances.” on page 6-37 for more information.
NavigationPREVIOUS
MENU page 11-4
Move Cutter To Access Location
page 11-9
Start Tool Calibration page 12-1
• Start Tool Calibration: Enters the Tool Changer calibration menu. For details on calibrating the Tool Changer, see page 12-1 for more information.
• Move Cutter To Access Location: Moves the cutter gantry to a location close to the Tool Changer access gate, so the operator can manually change tools. The STOP button on the Operator’s Station must be pressed for the manual tool changer air valve to be activated.
• Previous Menu: Displays the previous menu which in the case is the Main menu. See page 11-4 for more information.
Alliance Series 11-9
Manual Run
PREVIOUS MENU
page 11-4
REVERSE SLOW FORWARD
M A N U A L F E E DDISABLE
AUTO FEED
Download Received MODBUS-MODE
Manual Feed
Navigation
Setup ModeOFFUNCLAMP DOOR
STOP
MANUAL WIDTH ADJUST
JOG JOG
MAINTE-NANCE
TROUBLE SHOOT
JOG CLOSE JOG OPEN
DISABLEAUTO ADJUST
Control
Manual Width Adjust Control
Feed Controls
REVERSE SLOW FORWARD
M A N U A L F E E D DISABLEAUTO FEEDJOG JOG
• Jog Reverse: Moves the feed in the reverse direction.• Fast: Pressing this button in conjunction with Jog Reverse or Jog Forward puts the feed in fast
mode. • Jog Forward: Moves the feed in the forward direction.• Disable/Enable Auto Feed: Enable or disable auto-feed feature. If enabled, the auto-feed system
operates normally. If disabled, the feed system must be operated manually.
• Width Adjust Controls
Setup ModeOFFUNCLAMP DOOR
STOP
MANUAL WIDTH ADJUST
JOG CLOSE JOG OPEN
DISABLEAUTO ADJUST
• Jog Close: Manually closes the width adjust.• Jog Open: Manually opens the width adjust. • Disable/Enable Auto Adjust: Enable or disable auto-adjust feature. If enabled, the fence width
adjusts to the size of the incoming door. If disabled, no door width adjustment is made. It retains its state after power is turned off.
• Clamp/Unclamp: Toggles door clamp between clamped and unclamped. • Door Stop: Toggles door stop between up and down.• Setup Mode ON/OFF: Turn on/off setup mode. While in setup mode, the machine goes through all
operations as it would normally, but the cutter does not plunge in to cut the door. It is used to test new templates before actually cutting a door.
11-10 Alliance Series
Touch Screen
NavigationPREVIOUS
MENU page 11-4
MAINTE-NANCE
TROUBLE SHOOT
• Trouble Shooting: Opens the trouble shooting menu.• Maintenance: Opens the Maintenance menu• Previous Menu: Returns to the previous menu
Alliance Series 11-11
11-12 Alliance Series
Changing a Tool Manually
For normal operations, the tool is changed automatically, where the DL-NCC is programmed inthe Door File to select the tool appropriate to the door material. However, you can manuallychange the tool if you wish (for example, to change a dull bit, if there is a mechanical problemwith the tool changer, or if you want to replace the tool when the machine is off).
To Change a Tool Manually
NOTE: After you manually change the tool, you will also have to home the machine – see “Homing the DLNCC” on page 11-17 for instructions.
1.
While holding the toolwith the other hand, pullthis button to release thetool from the motor.
Grasp the toolfirmly by the collet.
With one hand, hold the tool firmly (grasp by the collet).
Be sure to hold it firmly, as it would otherwise fall when it is released from the motor.2.Using your other hand, pull out the
black Tool Release button on the top left side of the motor to release the tool from the motor spindle.
NOTE: Make sure to pull the button out until it clicks in the ON position (motor spindle stays in the unclamped position). Leave the button in this position until instructed to push it in later in this procedure.
3.Once the tool is released from the motor, slide it down and away from the motor. Set the old tool aside.
4.Using one hand, insert the new tool into the spindle. Be sure to push the tool all the way up until the collet can go no farther into the spindle.
5.While holding the tool firmly in place, use your other hand to push in the Tool Release button.
Do not let go of the tool until the spindle clamping assembly pulls the collet up into place.
!
!
Alliance Series 11-13
Changing a Tool Bit
Use the procedure below to change the bit in a tool (involves removing the old bit from the collet and installing a new bit).
To Change a Tool Bit
1.Retrieve the open-end wrench and the collet wrench from the toolbox that ships with the machine.2.Set the tool on a flat, stable surface.3.As shown in the illustration below, slide the open-end wrench on the collet housing and insert the col-
let wrench on the collet nut. Loosen the collet nut until the bit becomes loose.
Tool (assembled) Tool (fully disassembled)
ColletAssembly
Bit
Collet
ColletHousing
Collet Nut
11-14 Alliance Series
4.As shown in the illustration below, remove the old bit and insert the new bit.
5.Before clamping the bit in place, make sure the distance between the top edge of the bit’s cutting sur-face and the bottom of the collet is 1-1/16 inches.
1-1/16”
6.As shown in the illustration below, use the open-end wrench to hold the collet in place and use the col-let wrench to tighten the bit firmly in the collet.
Alliance Series 11-15
11-16 Alliance Series
Homing the DLNCC
Homing the DLNCCThe DLNCC must go through a homing routing before any other operation is performed. Performing the homing routine establishes a home position - a zero-reference position from which the Face mea-sures its motion when making cuts.You should home the DLNCC:
• After powering up the system• After hitting the STOP then START buttons• When recovering from an Emergency Stop
To Home the DLNCC
1. Remove any doors from the feed system.2. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button
below it to read Home.3. Click twice on the Home button. The Face should start the homing operation.
NOTE:While the homing operation is in progress, the Home button changes its label to Homing.
Alliance Series 11-17
11-18 Alliance Series
CHAPTER 12 Calibrating the DL-NCC
This section provides detailed procedures for calibrating the Tool Changer (see below) and for calibrat-ing the cut accuracy (see “Calibrating Cut Accuracy” on page 12-14).Note: If, after making the initial calibrations, you discover cut inaccuracy, refer to the streamlined rem-edy procedures in the Troubleshooting chapter (see “Correcting Cut Accuracy Problems” on page 12-17).
Calibrating the DL-NCC Tool Changer
The tool changer must be calibrated to make sure the DL-NCC can find and select the appropriate tool when the program calls for it.There are three potential stages you can use for calibrating the Tool Changer:
• Tool Calibration, Stage 1: Calibration Bolt (page 12-3)• Tool Calibration, Stage 2: Tool Offset (page 12-8)• Tool Calibration, Stage 3: Tool Holders (page 12-12)
Determining Which Calibration Stage to Use
Use the following as a guide to find out which Tool Calibration stage is required:• If the error message “Tool Change Error. Calibration Bolt Not Aligned” is displayed, Tool Calibra-
tion Stage 1 is required.• If there is difficulty retrieving the tool in position #1, Tool Calibration Stage 2 is required.• If a new tool holder has been installed or if the tool in position #1 can be retrieved correctly but there
is difficulty retrieving the tools in the other positions, Tool Calibration Stage 3 is required.Note: Before calibrating the Tool Changer, you must first complete the Preparing to Calibrate the Tool
Changer procedure (see below).
Preparing to Calibrate the Tool Changer
1.If the machine is presently processing doors, do one of the following:a.If you need to cancel a cut in progress, in the KVAL 2006 interface, press the ABORT button (or press the F1 key) and then the Restart button (or press the F2 key).b.If you wish to finish the present door, but prevent any subsequent doors from being processed, in the KVAL 2006 interface, press the Override Count button.
Alliance Series 12-1
Calibrating the DL-NCC
2.
PREVI-OUS
MENU
M-2001
M2040
M-2041
M-2042
M-2043
I-41I-42I-43I-44
CR-2001:CUTTER MOTOR
CR-2040:SPEED #1
CR-2041:SPEED #2
CR-2042:SPEED #3
CR-2043:CUTTER WARMUP
CR-41: MOTOR STOPPED
CD-42: ARBOR EXTENDED
I-43: TOOL IN & RETRACTED
I-44: RETRACTED & LOCKED
TOOL CHANGER
8 7 6 5 4 3 2 1Tools Found in Holder
Current Tool In Use 1MOTOR WARM UP
Current Tool Speed 5100%
Move Cutter To Access Location
Start Tool Calibra-
tion
PREVIOUS MENU
TOOL LOCATION CALIBRATION
STAGE 1 page 12-3
STAGE 2 page 12-8
STAGE 3 page 12-12
Set Location of calibration bolt
Determine distance betweeneye and cutter head
Position tool holders
MANUAL RUN
TOOL CHANGER
OFF AUTO FEEDTHRU REVERSE
F E E D M O D E
S E L E C T T O O L
OSCILLATEON
EJECTOFF
RETURNTOOL
Download Received Motor Warm-upMODBUS-MODE
173-SCN1_1v1
100%
DISABLE TOOL
TOOL-4 TOOL-3 TOOL-2 TOOL-1AVAILABLE SELECTED AVAILABLE DISABLE
STEEL
FIBERGLASS
TOOL-8 TOOL-7 TOOL-6 TOOL-5DISABLE DISABLE SELECTED SELECTED
EMPTY EMPTY DRILL
FIBERGLASS FIBERGLASS FIBERGLASS
Access the Tool Changer screen on the Touchscreen interface. To access the Tool Changer screen:
a.From the Main menu press Tool Changer.b.On the Tool Changer menu press Start Tool Calibration.
3.After you access the Tool Calibration screen, proceed to the calibration proce-dure prescribed by the Determining Which Calibration Stage to Use guide-lines on page 12-1. • Stage 1: go to page 12-3. • Stage 2: go to page 12-8. • Stage 3: go to page 12-12.
12-2 Alliance Series
Tool Calibration, Stage 1: Calibration Bolt
Use Stage 1 to center the Calibration Eye to the Calibration Bolt.1.Clear the “Tool Change Error. Calibration Bolt Not Aligned” alert. You will correct the calibration in
the remaining steps of this procedure.
Tool Change Error. Calibration Bolt Not Aligned.[Click to Clear]
2.Make sure all tool positions are disabled.a.On the Main Menu of the Touchscreen, press the Run Screen button to view the Run Screen. Then click the Disable Tools button to view the Disable Tools pop-up screen.
b.Make sure all Tool positions are disabled (OFF). If any Tool buttons are set to ON, press them so they display OFF. It should look like the Disable Tools pop-up screen shown above.
3.Home the machine. For instructions, see “Homing the DLNCC” on page 11-17.
MANUAL RUN
TOOL CHANGER
OFF AUTO FEEDTHRU REVERSE
F E E D M O D E
S E L E C T T O O L
OSCILLATEON
EJECTOFF
RETURNTOOL
Download Received Motor Warm-upMODBUS-MODE
173-SCN1_1v1
100%
DISABLE TOOL
TOOL-4 TOOL-3 TOOL-2 TOOL-1AVAILABLE SELECTED AVAILABLE DISABLE
STEEL
FIBERGLASS
TOOL-8 TOOL-7 TOOL-6 TOOL-5DISABLE DISABLE SELECTED SELECTED
EMPTY EMPTY DRILL
FIBERGLASS FIBERGLASS FIBERGLASS
CLOSE-MENU
Tool-4OFF
Tool-3OFF
Tool-2OFF
Tool-1OFF
Tool-8OFF
Tool-7OFF
Tool-6OFF
Tool-5OFF
DISABLE TOOLSIf all OFF, machine doesnot scan tools on Home
Main Menu
Disable Tools Pop-up
Alliance Series 12-3
Calibrating the DL-NCC
4.Navigate to the main Tool Calibration screen (for navigation help, see page 12-2) and press the Stage 1 button to access the Stage 1 screen.
PREVIOUS MENU
TOOL LOCATION CALIBRATION
STAGE 1
STAGE 2
STAGE 3
Set Location of calibration bolt
Determine distance betweeneye and cutter head
Position tool holders
Tool Calibration Screen
Tool Calibration Stage 1 screen
PREVIOUS MENU
Tool Location Calibration Stage 1
Toggle Head Position
Calibration Bolt
BetweenOver Calibration Bolt andAway from Calibration Bolt
ToggleHead Position
HELP
5.ToggleHead Position
Press the Toggle Head Position button one time and verify that the machine moves cutter head to a position approximately five inches away from the Calibration Bolt.
6.ToggleHead Position
Press the Toggle Head Position button one more time. This will move the carriage so the Calibra-tion Eye should be over the Calibration Bolt. If the eye is not centered over the Calibration Bolt, fol-low the steps listed below.
12-4 Alliance Series
7.Maint
Cal
In the KVAL 2006 interface, click once on the Maint button.8.Click the CAL button.
You will see a message pop up in front of the graphic display area. This is a warning message,informing you that if you proceed, it will abort any cutout program that is running.
Calibration and Jog will Abort ProgramHit Esc or exit to cancel
[Click to Clear]
Click on the pop-up message to proceed.9.Cal OK? Click the Cal OK? button. The Calibration Menu page appears:
X
X Axis Y Axis Z AxisJog X Y and Z
< > < > < >STOP STOP STOP
4000 4000 4000
EXIT
Setup
Calibration
Galil
C:\ \Dataline\Door.dbf\Dataline\Lock.dbf\Dataline\DoorNum.dbf\Dataline\LockDlnc.dbf\Doorlite\DLNC2004.cal\Doorlite\DLNCHome.cal
[Space Bar to Stop]
Calibration Menu
10.Calibration Click the Calibration button. This takes you to the calibration pages where the calibration takes place. The first page displayed is Calibration Page 1:
X
EXIT
Protection Cal
Jog Menu
Galil
Calibration Page 1
Page Up
Page Down
DoorNum.dbf List1) 618 Door Count=6182) Face 14) Face 26) Face 38) Face 410) Edge 112) Edge 214) Edge 316) Archdidm718) Archdi420) A,26 (5)
- Stop Location Calibration (X-Axis)Primary Infeed Stop(1) .646 + 0 = 0.646
Primary Outfeed Stop(1) 106.692 + 7.312 =114.004
- Cutter Head Calibration Values (Y Axis)Y Calibration(1) .265 + 0 = .265
- Cutter Depth Calibration (Z Axis)Cutter Plunge Depth Cal(1) 0 + 0 = 0.000
Cutter Max Plunge Cal 1.00 + 0 =1.000Shallow Cut Depth Cal .25 + 0 = .250
Slow Plunge Speed Factor .020 + 0 = .020
Alliance Series 12-5
Calibrating the DL-NCC
11.Page Up
Click the Page up button once to access Calibration Page 2 (Tool Changer Calibration):X
EXIT
Protection Cal
Jog Menu
Galil
Calibration Page 2
Page Up
Page Down
DoorNum.dbf List1) 618 Door Count=6182) Face 14) Face 26) Face 38) Face 410) Edge 112) Edge 214) Edge 316) Archdidm718) Archdi420) A,26 (5)
- Width Adjust CalibrationWidth Adjust Calibration(1) .250 + 0 = .250
Width Adjust Tolerance(1) 0.50 + 0 =.500Width Open After Unclamp(1) .949 + -.400 =.549
-Tool Changer CalibrationTool Alignment Bolt X(1) 120.076 + 0 =120.076Tool Alignment Bolt Y(1) 37.411 + 0 =37.411
Tool Location Offset X(1) 2.855 + 0 =2.855Tool Location Offset Y(1) 15.237 + .031 =15.268Tool Location Offset Z(1) 0.000 + .062 =.062
12.Look at the placement of the Calibration Eye relative to the Calibration Bolt. Measure and record any misalignment along the X axis (length of the machine) and along the Y axis (across the width of the machine). Any misalignments will be entered as offsets in the Calibration Page as noted below.
13.If the Calibration Eye is out of alignment along the X axis (length of DL-NCC), adjust the Tool Alignment according to the following sub-procedure. If there is no misalignment along the X axis, skip to Step 14.
a.Locate the Tool Alignment Bolt X(1) area on the Calibration Page.b.Integrate the Modifier (if needed):
If the right-hand field has a value other than zero, click the left-most field to integrate the value. The result should update the left-most field. Before proceeding to the next step, verify that the right-hand field is empty or shows zero.Example:
c.Type the offset in the right-hand field, press the Enter key, and then click the leftmost field to register the new offset. If the Calibration Eye needs to move toward the out-feed end of the machine, enter a negative value. If the Calibration Eye needs to move toward the in-feed end of the machine, enter a positive value.
98.815 + 2.180 =100.693 (Modifier field has a non-zero value)
98.815 + 2.180 =100.693 (Click on the left-most field)
100.693 + =100.693 (Offset is updated, Modifier field is empty)
X
12-6 Alliance Series
Example:If the Calibration Eye needs to move ¼ inch toward the out-feed end of the machine, type “-1/4” or “-0.250” in the field and press the Enter key. Then click the left-most field to record the offset value. This process is illustrated below:
-Tool Changer CalibrationTool Alignment Bolt X(1) 97.584 + -0.250 = 97.584
Press the Enter key.
-Tool Changer CalibrationTool Alignment Bolt X(1) 97.584 + -.250 = 97.584
Click the left-hand field (updates with final offset value).
-Tool Changer CalibrationTool Alignment Bolt X(1) 97.334 + = 97.584
14.If the Calibration Eye is out of alignment along the Y axis (across the width of the DL-NCC machine), adjust the Tool Alignment according to the following sub-procedure. If there is no misalign-ment along the Y axis, skip to Step 15.
a.Locate the Tool Alignment Bolt Y(1) area on the Calibration Page.
b.If the right-hand field has a non-zero value, click the left-most field to update the offset before proceeding (see the “Integrate the Modifier” example on page 12-6).c.Type the offset in the right-hand field, press the Enter key, and then click the leftmost field to register the new offset. If the Calibration Eye needs to move toward the fixed fence side of the machine, enter a negative value. If the Calibration Eye needs to move toward the adjustable fence side of the machine, enter a positive value. (see example in Step 13.c. above)
15. When you are finished making the calibration adjustments, click the Exit button. This exits the Cali-bration page and the KVAL 2006 program.
16. Re-launch the KVAL 2006 program.17. Home the machine.18. Verify the Calibration during the homing operation.
As part of the homing operation, after the cutter head reaches the Home position, it will travel to the Tool Changer location and check to make sure the Calibration Eye is aligned with the Calibration Bolt. If the DL-NCC detects misalignment between the Eye and the Bolt, the KVAL 2006 Interface will dis-play the following alert:
Tool Change Error. Calibration Bolt NotAligned.[Click to Clear]
If you see the alert, clear the alert and repeat the Stage 1 procedure.If you do not see an alert, Stage 1 calibration is complete.
Tool Alignment Bolt Y(1) 37.573 + 0 = 37.573
Alliance Series 12-7
Calibrating the DL-NCC
Tool Calibration, Stage 2: Tool Offset
Use Stage 2 to calibrate the distance between the Calibration Eye and the center of the cutter motor at Tool Holder position # 1. If the cutter head has problems picking up or returning the tool to Tool Holder position #1, this is the stage that allows you to correctly calibrate the offset between the Calibration Eye and the center of the cutter motor.1. Move the cutter head down to the in-feed end of the machine, where the tool can be removed:
In the Touchscreen panel, from the Main Menu, press the Tool Changer button. In the Tool Changer screen, press the Move Cutter To Access Location button to move the cutter gantry to the in-feed end of the machine.
2.If there is a tool in the cutting head remove the tool manually.IMPORTANT: Leave the tool in Tool Holder position #1 for this procedure.
MACHINE
START
STOP
a. Press the STOP button on the Operator’s Station control panel. This leaves the control circuits on and turns off all machine drives.b.Open the Safety Gate and proceed to the Tool Changer area.c.Remove the tool from the Cutter Head:
!
i) With one hand, hold the tool firmly (grasp by the collet).
Be sure to hold it firmly, as it would otherwise fall when it is released from the motor.
ii) Using your other hand, pull out the black Tool Release button on the top left side of the motor to release the tool from the motor spin-dle.iii) Once the tool is released from the motor, slide it down and away from the motor. Set the old tool aside.iv) Push in the black Tool Release button.v) Insert tool into the proper tool holder.
MANUAL RUN
TOOL CHANGER
OFF AUTO FEEDTHRU REVERSE
F E E D M O D E
S E L E C T T O O L
OSCILLATEON
EJECTOFF
RETURNTOOL
Download Received Motor Warm-upMODBUS-MODE
173-SCN1_1v1
100%
DISABLE TOOL
TOOL-4 TOOL-3 TOOL-2 TOOL-1AVAILABLE SELECTED AVAILABLE DISABLE
STEEL
FIBERGLASS
TOOL-8 TOOL-7 TOOL-6 TOOL-5DISABLE DISABLE SELECTED SELECTED
EMPTY EMPTY DRILL
FIBERGLASS FIBERGLASS FIBERGLASS
PREVI-OUS
MENU
M-2001
M2040
M-2041
M-2042
M-2043
I-41I-42I-43I-44
CR-2001:CUTTER MOTOR
CR-2040:SPEED #1
CR-2041:SPEED #2
CR-2042:SPEED #3
CR-2043:CUTTER WARMUP
CR-41: MOTOR STOPPED
CD-42: ARBOR EXTENDED
I-43: TOOL IN & RETRACTED
I-44: RETRACTED & LOCKED
TOOL CHANGER
8 7 6 5 4 3 2 1Tools Found in Holder
Current Tool In Use 1MOTOR WARM UP
Current Tool Speed 5100%
Move Cutter To Access Location
Start Tool Calibra-
tion
Pressing this button moves the Cutter Gantry to the infeed end of machine, for easy access.
While holding the toolwith the other hand, pullthis button to release thetool from the motor.
Grasp the toolfirmly by the collet.
12-8 Alliance Series
d.Make sure to leave a tool in Tool Holder position #1.e.Close the Safety Gate.f.Turn the machine back on by pressing the START button on the Operator’s Station control panel.
3.Home the machine. For instructions, refer to “Homing the DLNCC” on page 11-17.NOTE: The homing procedure will produce the following error:
No Tool In Cutter Head Warm-up Not Started
[Click to Clear]
This is a normal condition for Stage 2 calibration. Click the alert pop-up to clear it and move to the next step.
4.Navigate to the main Tool Calibration screen (for navigation help, see page 12-2) and press the Stage 2 button to access the Stage 2 screen.
PREVIOUS MENU
TOOL LOCATION CALIBRATION
STAGE 1
STAGE 2
STAGE 3
Set Location of calibration bolt
Determine distance betweeneye and cutter head
Position tool holders
Tool Calibration Screen
Tool Calibration Stage 2 screen
PREVIOUS MENU
Tool Location Calibration Stage 2
Toggle Head Position
Tool Offset
BetweenCalibration and Tool 1
ToggleHead Position
HELP
5.ToggleHead Position
Press the Toggle Head Position button one time and verify that the machine responds as follows:
Motor is positioned over the center of Tool #1
• Moves the cutter head to the in-feed end of the machine. The Calibration Eye should be over the Calibration Bolt.
• Moves the Tool Changer arm in toward the center of the machine, as it does during a tool change.
6.ToggleHead Position
Press the Toggle Head Position button again and verify that the machine responds by moving the cutter head so that the center of the cutter motor is centered over Tool Holder #1.
7.Look at the cutter motor clamping cone in relationship to the center of the collet on tool #1. If the center of the cutter motor is not centered over the tool, write down the amount it is off, both along the X axis (length of DL-NCC) and the Y axis (width of DL-NCC). Then proceed to the next step.
Alliance Series 12-9
Calibrating the DL-NCC
8.Maint
Cal
In the KVAL 2006 interface, click once on the Maint button.9.Click the CAL button.
You will see a message pop up in front of the graphic display area. This is a warning message,informing you that if you proceed, it will abort any cutout program that is running.
Calibration and Jog will Abort ProgramHit Esc or exit to cancel
[Click to Clear]
Click on the pop-up message to proceed.10.Cal OK? Click the Cal OK? button. The Calibration Menu page appears:
X
X Axis Y Axis Z AxisJog X Y and Z
< > < > < >STOP STOP STOP
4000 4000 4000
EXIT
Setup
Calibration
Galil
C:\ \Dataline\Door.dbf\Dataline\Lock.dbf\Dataline\DoorNum.dbf\Dataline\LockDlnc.dbf\Doorlite\DLNC2004.cal\Doorlite\DLNCHome.cal
[Space Bar to Stop]
Calibration Menu
11.Calibration Click the Calibration button. This takes you to the calibration pages where the calibration takes place. The first page displayed is Calibration Page 1:
X
EXIT
Protection Cal
Jog Menu
Galil
Calibration Page 1
Page Up
Page Down
DoorNum.dbf List1) 618 Door Count=6182) Face 14) Face 26) Face 38) Face 410) Edge 112) Edge 214) Edge 316) Archdidm718) Archdi420) A,26 (5)
- Stop Location Calibration (X-Axis)Primary Infeed Stop(1) .646 + 0 = 0.646
Primary Outfeed Stop(1) 106.692 + 7.312 =114.004
- Cutter Head Calibration Values (Y Axis)Y Calibration(1) .265 + 0 = .265
- Cutter Depth Calibration (Z Axis)Cutter Plunge Depth Cal(1) 0 + 0 = 0.000
Cutter Max Plunge Cal 1.00 + 0 =1.000Shallow Cut Depth Cal .25 + 0 = .250
Slow Plunge Speed Factor .020 + 0 = .020
12-10 Alliance Series
12.Page Up
Click the Page up button once to access Calibration Page 2 (Tool Changer Calibration):X
EXIT
Protection Cal
Jog Menu
Galil
Calibration Page 2
Page Up
Page Down
DoorNum.dbf List1) 618 Door Count=6182) Face 14) Face 26) Face 38) Face 410) Edge 112) Edge 214) Edge 316) Archdidm718) Archdi420) A,26 (5)
- Width Adjust CalibrationWidth Adjust Calibration(1) .250 + 0 = .250
Width Adjust Tolerance(1) 0.50 + 0 =.500Width Open After Unclamp(1) .949 + -.400 =.549
-Tool Changer CalibrationTool Alignment Bolt X(1) 120.076 + 0 =120.076Tool Alignment Bolt Y(1) 37.411 + 0 =37.411
Tool Location Offset X(1) 2.855 + 0 =2.855Tool Location Offset Y(1) 15.237 + .031 =15.268Tool Location Offset Z(1) 0.000 + .062 =.062
13.Regarding the cutter motor clamping cone in relationship to the center of the collet on tool #1, if the cutter motor is out of alignment along the X axis (along the length of DL-NCC), adjust the Tool Loca-tion Offset according to the following sub-procedure. If there is no misalignment along the X axis, skip to Step 14.
a. Locate the Tool Location Offset X(1) area on the Calibration Page.b. If the right-hand field has a non-zero value, click the left-most field to update the offset before proceeding (see the Integrate the Modifier example on page 12-6).c. Type the offset in the right-hand field, press the Enter key, and then click the leftmost field to register the new offset. If the cutter motor needs to move toward the out-feed end of the machine, enter a negative value. If the cutter motor needs to move toward the in-feed end of the machine, enter a positive value.
Example:If the cutter motor needs to move ¼ inch toward the in-feed end of the machine, type 1/4” or “0.250” in the field and press the Enter key. Then click the left-most field to record the offset value. This pro-cess is illustrated below:
Tool Location Offset(1) 3.257 + 0.250 = 3.257
Press the Enter key.Tool Location Offset(1) 3.257 + 0.250 =3.507
Click the left-hand field (updates with final offset value).Tool Location Offset(1) 3.507 + = 3.507
14.If the cutter motor is out of alignment along the Y axis (across the width of the DL-NCC machine), adjust the Tool Location Offset according to the following sub-procedure. If there is no misalignment along the Y axis, skip to Step 15.
a.Locate the Tool Location Offset Y(1) area on the Calibration Page.
b.If the right-hand field has a non-zero value, click the left-most field to update the offset before proceeding (see the “Integrate the Modifier” example on page 12-6).c.Type the offset in the right-hand field, press the Enter key, and then click the leftmost
Tool Alignment Bolt Y(1) 37.573 + 0 = 37.573
Alliance Series 12-11
Calibrating the DL-NCC
d.Type the offset in the right-hand field, press the Enter key, and then click the leftmost field to register the new offset. If the cutter motor needs to move toward the fixed fence side of the machine, enter a negative value. If the cutter motor needs to move toward the adjustable fence side of the machine, enter a positive value. (see example in Step 13.c. above)
15.EXIT When you are finished making the calibration adjustments, click the Exit button. This exits the Cal-ibration page and the KVAL 2006 program.
16. Re-launch the KVAL 2006 program.17. Click on the Abort button, then the Load Programs button at the bottom right corner of the
KVAL 2006 interface screen.18. Stage 2 calibration is complete.Note: Tool Location Offset Z(1) is factory set, adjustment should be unnecessary.
Tool Calibration, Stage 3: Tool Holders
Use Stage 3 to fine-tune the alignment of the cutter motor with one or more tool holders. In this process, you loosen the tool holders where the tool is not being retrieved correctly, then move the cutter motor (with a tool inserted) from one tool holder to the next, tightening each tool holder as you go.This alignment is usually required only when the machine is being set up for the first time or if the tool holder has just been replaced.1.
MACHINE
START
STOP
Turn off the machine by pressing the STOP button on the Operator’s Station control panel. This leaves the control circuits on and turns off all machine drives.
2. Open the gate near the tool changer.3. Remove the tools from all tool holders where the tool is not being retrieved
correctly. Refer to the photos below for proper tool removal technique.
Push the tool out, using both hands. Tool is released from Tool Holder
Note: If there is an empty tool position that does not need calibration, disable the tool position. Refer to the instructions on page 12-3.
12-12 Alliance Series
4.If a tool is not already inserted in the Cutter Head, manually insert a tool into the cutter head:a. Locate the black Tool Release button on the top left side of the motor.b.Using one hand, pull out the Tool Release but-ton. The clamping cone on the cutter head will come down. Leave the Release button in the ON (pulled out) position.c. Using your other hand, insert the tool into the motor spindle. Be sure to push the tool all the way up until the tool can go no farther into the spindle.d. While holding the tool firmly in place, push in the Tool Release button.
!Do not let go of the tool until the tool is pulled
up into place.
5. Using a ½-inch hex wrench, loosen the empty tool holders just enough so they will move a little bit.
6. Close the safety gate.7. Turn the machine back on by pressing the START button on the Operator’s Station control panel.8. Home the machine. For instructions, refer to “Homing the DLNCC” on page 11-17.9. Navigate to the main Tool Calibration screen (for navigation help, see page 3-22) and press the Stage 3 button to access the Stage 3 screen.
PREVIOUS MENU
TOOL LOCATION CALIBRATION
STAGE 1
STAGE 2
STAGE 3
Set Location of calibration bolt
Determine distance betweeneye and cutter head
Position tool holders
Tool Calibration Screen
Tool Calibration Stage 3 screen
PREVIOUS MENU
Tool Location Calibration Stage 3
This Mode is Used
Tool Holders
To Adjust Tool Holders
NextStep
HELP
10.NextStep
Press the Next Step button one time and verify that the machine responds as follows:• The cutter head moves down to the Tool Changer and scans the Calibration Bolt.• It will then scan all the tool holders to see which ones are empty (it will only move the tool with the
collet into the tool holders that do not already have a tool in them.).• The cutter head will move the tool into the first available empty tool holder.
Tool Release button
Alliance Series 12-13
Calibrating the DL-NCC
11. Repeat the following sub-procedure to fine-tune the position of each empty tool holder:a. Open the gate.b. Tighten the tool holder bolts securely.c. Close the gate and return to the Operator’s Station.
d. In the KVAL 2006 interface on the PC, press ABORT , then Restart .e.Next
Step If there is another tool holder that remains to be tightened, press the Next Step button. The
head will move the tool into the empty tool holder.12. After all the tool holders are bolted securely in place, Stage three is complete.
NOTE: Be sure to close the Safety Gate.13. Press the BACK button as needed to exit to the desired screen on the Touchscreen panel.14. Replace all tools to their respective Tool Holder positions.15. Stage 3 calibration is complete.
Calibrating Cut Accuracy
The DL-NCC needs to be calibrated so that the cuts and holes are started at the correct X and Y coordi-nates.
To Calibrate the Cut Accuracy
1. Create a baseline cut on a LH (left-hand) door. LH doors use the Primary Stop (located at the out-feed end of the machine):
a. Create and download a LH door file to make a rectangular cut with these specifications: 10 inches from the top (X) and 10 inches from the side (Y), 5 inches long and 5 inches wide.b. Measure the cut accuracy. Measure the distance from the top of the door to the top of the cut (X axis), and measure the distance from the side of the door to the nearest side of the cut (Y). Write down these measurements and note any inaccuracies from the expected values.
2. Create the same baseline cut, from Step 1, on a RH (right-hand) door. RH doors use the Secondary Stop (located at the in-feed end of the machine).
Primary Stop
X = 10”
Y = 10”5”X5” cut
Lock Side
Hinge S
ide
FeedDirection
Top of Door
Secondary Stop
X = 10”
Y = 10”5”X5” cut
Lock
Sid
e
Hin
ge S
ide
FeedDirection
Top of DoorStep 1 Cut Step 2 Cut
X Location 10.000Y Location 10.000Length 5.000Width 5.000
12-14 Alliance Series
3.If there are inaccuracies in the cuts, adjust the calibration settings:4.Maint
Cal
In the KVAL 2006 interface, click once on the Maint button.5.Click the CAL button.
You will see a message pop up in front of the graphic display area. This is a warning message,informing you that if you proceed, it will abort any cutout program that is running.
Calibration and Jog will Abort ProgramHit Esc or exit to cancel
[Click to Clear]
Click on the pop-up message to proceed.6.Cal OK? Click the Cal OK? button. The Calibration Menu page appears:
X
X Axis Y Axis Z Axis
Jog X Y and Z
< > < > < >STOP STOP STOP
4000 4000 4000
EXIT
Setup
Calibration
Galil
C:\ \Dataline\Door.dbf\Dataline\Lock.dbf\Dataline\DoorNum.dbf\Dataline\LockDlnc.dbf\Doorlite\DLNC2004.cal\Doorlite\DLNCHome.cal
[Space Bar to Stop]
Calibration Menu
7.Calibration Click the Calibration button. This takes you to the calibration pages where the calibration takes place. The first page displayed is Calibration Page 1:
X
EXIT
Protection Cal
Jog Menu
Galil
Calibration Page 1
Page Up
Page Down
DoorNum.dbf List1) 618 Door Count=6182) Face 14) Face 26) Face 38) Face 410) Edge 112) Edge 214) Edge 316) Archdidm718) Archdi420) A,26 (5)
- Stop Location Calibration (X-Axis)Primary Infeed Stop(1) .646 + 0 = 0.646
Primary Outfeed Stop(1) 106.692 + 7.312 =114.004
- Cutter Head Calibration Values (Y Axis)Y Calibration(1) .265 + 0 = .265
- Cutter Depth Calibration (Z Axis)Cutter Plunge Depth Cal(1) 0 + 0 = 0.000
Cutter Max Plunge Cal 1.00 + 0 =1.000Shallow Cut Depth Cal .25 + 0 = .250
Slow Plunge Speed Factor .020 + 0 = .020
Alliance Series 12-15
Calibrating the DL-NCC
8.If there is inaccuracy in the X coordinate for cuts on an LH door, adjust the Primary Stop setting. Oth-erwise, skip to Step 9.
a. Locate the Primary Stop-Outfeed(1) area on the Calibration Page.b. If the right-hand field has a non-zero value, click the left-most field to update the offset before proceeding (see the Integrate the Modifier example, page 12-6).c. Type the offset in the right-hand field, press the Enter key, and then click the left-most field to register the new offset. If the cut needs to move toward the top of the door, enter a negative value. If the cut needs to move away from the top of the door, enter a positive value.
For example, if the cut needs to move. inch toward the top of the door, type g-1/4h or g-0.250h in the field and press the Enter key. Then click the left-most field to record the offset value.
This process is illustrated below:-Stop Location Calibration (X-Axis)
Primary Stop-Outfeed(1) .171 + -0.250 = .171
Press the Enter key.Click the left-hand field (updates with final offset value).
-Stop Location Calibration (X-Axis)Primary Stop-Outfeed(1) .079 + = .079
9. If there is inaccuracy in the X coordinate for cuts on an RH door, adjust the Secondary Stop setting. Otherwise, skip to Step 10.
a. Locate the Secondary Stop-Outfeed(1) area on the Calibration Page.
b. If the right-hand field has a non-zero value, click the left-most field to update the offset before proceeding.c. Type the offset in the right-hand field, press the Enter key, and then click the left-most field to register the new offset. If the cut needs to move toward the bottom of the door, enter a negative value. If the cut needs to move away from the bottom of the door, enter a positive value. (see example in 8-c above)
10.g. If there is inaccuracy in the Y coordinate for the cut, adjust the Y Calibration setting. Otherwise, skip to Step 11.
a. Locate the Y Calibration(1) area on the Calibration Page.
b. If the right-hand field has a non-zero value, click the left-most field to update the offset before proceeding.c. Type the offset in the right-hand field, press the Enter key, and then click the left-most field to register the new offset. If the cut needs to move toward the fixed fence of the DL-NCC, enter a negative value. If the cut needs to move away from the fixed fence of the DL-NCC, enter a pos-itive value. (see example in Step 8-c above)
11.EXIT When you are finished making the calibration adjustments, click the Exit button. This exits the Cal-ibration page and the KVAL 2006 program.
12. Re-launch the KVAL 2006 program.13. Click on the Abort button, then the Load Programs button at the bottom right corner of the
KVAL 2006 program screen.
Secondary Stop-Infeed(1) 98.180 + 0 = 98.180
-Cutter Head Calibration (Y and Z Axis)Y Calibration 0.000 + 0 =0.000
12-16 Alliance Series
14. VALIDATION: To verify that the calibration is correct and the cuts will be accurate, repeat Steps 1 and 2 to make new cuts and measure for any error. Repeat the same cuts on new doors, or make new cuts on the same doors but with these specifications: • 8 inches from the top (X) and 8 inches from the side (Y) X Location 8.000
Y Location 8.000Length 9.000Width 9.000
• 9 inches long and 9 inches wide15. If there are inaccuracies in the cuts, adjust the calibration settings accordingly
(refer back to Step 3 above), and then redo the validation.
Correcting Cut Accuracy Problems
For full details on calibrating the cut accuracy, refer to the procedure on page 12-14.
Cut Accuracy Problems DescriptionCut too low on Door using the outfeed end stop
Go to Calibration page 1 in the KVAL 2006 interface and locate Primary Stop-Outfeed (1).• Enter a negative number by the amount it is off in the right hand box
of Primary Stop-Outfeed (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.
Cut too high on Door using the outfeed end stop
• Enter a positive number by the amount it is off in the right hand box of Primary Stop-Outfeed (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.
Cut to low on Door using the in-feed end stop
Go to Calibration page 1 in the KVAL 2006 interface and locate Second-ary Stop-Infeed (1).• Enter a positive number by the amount it is off in the right hand box of
Secondary Stop-Infeed (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.
Cut to high on Door using the in-feed end stop
• Enter a negative number by the amount it is off in the right hand box of Secondary Stop-Infeed (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.
Cut needs to be moved closure to the fixed fence
Go to Calibration page 1 in the KVAL 2006 interface and locate Y Cali-bration(1).• Enter a negative number by the amount it is off in the right hand box
of Y Calibration (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.
Cut needs to be moved away to the fixed fence
• Enter a positive number by the amount it is off in the right hand box of Y Calibration (1). If there already is a number in the right hand box, click on the left hand box first before entering a number in the right hand box.
Alliance Series 12-17
Calibrating the DL-NCC
12-18 Alliance Series
CHAPTER 13 RAIL
This chapter provides operating instructions for the KVAL Rail.
Alliance Series 13-1
RAIL
13-2 Alliance Series
Door Stack Access
Door Stack AccessThis Rail is equipped with Light Curtain safety devices. Breaking the light curtain beam has the same result as pushing an E-Stop. Power is removed from all motors, all servo systems, and all control cir-cuits. When enabled, the Light Curtains do not allow access to the door stacks. To enable access to the door stacks use the Door Stack Access Mode procedure shown below.
To Enable the Door Stack Access Mode:Light Curtain
Stack Access Area
Light Curtain
Stack Access Area
(RED) (RED)
(YELLOW) (YELLOW)
1.Press the Enable Access button.2.Wait for the Enable Access button and the blue light tower light to flash on and off.3.The Stack Area is available for access.
With Safety Skirt, Entry OK No Safety Skirt, No Entry
CAUTION: At this point there is still power to all motion control systems. • Do not enter the machine any further than the
stack access area indicated in yellow above.• Keep away from the door lift and the vacuum
clamp.• The lift must be equipped with a safety skirt. Do
not enter the stack access area if the safety skirt has been removed.
CAUTION: The Door Stack Access Mode allows access behind the machine’s light curtain safety devices and is for loading and unloading the door stacks ONLY. No maintenance should be performed in this mode. All controlling outputs are frozen. However, POWER IS STILL APPLIED TO ALL MOTION CONTROL SYSTEMS. In this mode a system failure could cause a motion control system to “run away” at full speed. DO NOT PUT YOURSELF IN A MOTION CONTROL SYSTEM’S PATH.
USE EXTREME CAUTION WHEN enabling the Door Stack Access Mode.
Alliance Series 13-3
To Disable the Door Stack Access Mode.
1.Ensure all personal are away from the machine and outside the light curtain.1.Pull out the Enable Access button.
The Enable Access button and the blue light tower light should turn off.The machine is now ready to resume work.
13-4 Alliance Series
Rail - Operator’s Tour
Rail - Operator’s Tour
Infeed End
Outfeed End
FeedDirection
Top View
Alliance Series - Rail 13-5
Operators Station:
Touch Screensee page 13-7
Control Panel
Control Panel
Control Transformer(Maintained)
PushOff
PullOn
MACHINE
START
STOP
Speed Select
70%80% 90%
100%
Router Depthof Cut
1.01.5 2.0
2.5
Faster
Reset Drives Disable Cycle(Maintained)
Vacuum
Off On
Control Panel
• Control Transformer: Applies electrical power to control circuits and computer
• Machine START STOP: Applies electrical power to drive circuits.
• Vacuum: Controls the Vacuum Clamp’s vacuum.• Speed Select: Sets the cutting speed. Use higher
settings for soft material, slower settings for hard material. If the speed ranges are not adequate for you needs please contact KVAL service.
• Reset Drives: Resets the motor drives.• Router Depth: Sets the depth of cut for each
router pass.• Disable Cycle: Stops the current lift and roll table
process.
13-6 Alliance Series
Touch Screen
Touch ScreenOK to Home
-12.452FORKLIFT00:NOT HOMED
I-41 RDY
CMD ACK12.73 11.50
112.327CARRIAGE00:NOT HOMED
I-40 RDY
CMD ACK09.13 10.52
107.022STOP00:NOT HOMED
I-42 RDY
CMD ACK06.24 05.48
MANUAL MODE
page 13-8O.K. TO HOME
Forklift StatusMessages
Carriage StatusMessages
Feed table StopMessages
Navigation & Control
• Manual Mode: Opens the Manual Mode screen. See page 13-8 for more details.• O.K. to Home: Starts the homing process.
The OK to Home button has three states:Yellow = OK to HomeRed = Unable to home. The ON2010 has found a condition that prohibits it from homing. Green = Homed.
Alliance Series - Rail 13-7
Main Menu REMOTE
MAINTE-NANCE
page 13-18
GO TO LOCAL
page 13-10
RESET
MB: OK
AUTOFEED
123.454
NO ACCESS
12.545117.352096.135
FORKCARRSTOPMB-DL
RDYRDYRDY
LIFT#1: ON
LOAD POS
PICK-UP
LOAD-POS
PICK-UP
STACK#2
STACK#1
STACK XFER2 -> 1
Stack Control
LASTDOOR Navigation
Feed Control
Feed Control
Toggles Auto Feed between ON and OFF.
When a door tagged as 'Last Door” enters the Rail machine no other doors are allowed into the rail. Pushing this button allows processing to continue.
Stack Control
STACK#2
STACK#1
Selects Stack #2 Selects Stack #1
LOAD POS
PICK-UP
Holding this button will
Holding this button will
raise the selected stack.
lower the selected stack.
AUTOFEED
RESETLASTDOOR
13-8 Alliance Series
Touch Screen
• Stack Transfer (STACK XFER)
STACK XFER2 -> 1
The Stack Transfer button (STACK XFER) allows doors to be moved from Stack #2 to Stack #1.Unload Doors
Here
From Previous
STACK XFER2 -> 1
Remove DoorsHere
Remove Doors Here
STACK XFER2 -> 1
STACK XFER2 -> 1
Stack Transfer ONStack Transfer OFF
Machine
MAINTE-NANCE
page 13-18
GO TO LOCAL
page 13-10
Navigation
• Go To Local: Opens the Main Menu LOCAL scree. See page page 13-10 for more information. • Maintenance: Opens the Maintenance screen. See page 13-18 for more information.
Alliance Series - Rail 13-9
Main Menu LOCAL
READY
MB: OK123.454 NO ACCESS
12.545117.352096.135
FORKCARRSTOPMB-DL
RDYRDYRDY
LIFT#1: ONENTER-DATA
MAINTE-NANCE
page 13-18
GO TO REMOTE page 13-8
AUTOFEED
LOAD POS
PICK-UP
LOAD-POS
PICK-UP
STACK#2
STACK#1
STACK XFER2 -> 1
Stack Control
NavigationFeed Control
Door LengthEntry
DOORLENGTH
72.2596.0060.25
110.75
DOOR LENGTH PRESET EDIT
Door Length Entry
Door Length Select:Steps through the four Door Length Presets
Doo
r Len
gth
Doo
r
Door Length Preset Edit:
Allows editing of door length preset values. For more information see “How to change a door length preset:” on page 13-11
DOORLENGTH
72.2596.0060.25
110.75
DOOR LENGTH PRESET EDIT
• Door Length Preset Edit:
40.25
SAVE & EXIT
PREVIOUS MENU
7 8 9
4 5 6
1 2 3
0 DEC(.)
FRC(/)
CLR
ENTER[DL-1]
DOOR-WIDTH 64.75 96.00 72.25110.75
DOOR-LENGTH-1DL-1DL-2DL-3DL-4
60.2596.0072.25
110.75
PRESET NEW
MAX. DOOR-LENGTH = XX.XX
DOOR LENGTH PRESET EDIT The Door Length Preset Edit
button Calls the Door Length Edit screen shown below. Use this screen to modify the door four length presets.
13-10 Alliance Series
Touch Screen
How to change a door length preset:
1.Use the Door Length Preset selector button to scroll to the desired preset.
DOOR-LENGTH-1DL-1DL-2DL-3DL-4
2.Use the Key Pad to enter the new door length preset value. The keyed in value will appear in the Key Pad Display. Fractional values can be entered as decimal number or fractions (see page 13-12). The value entered must be less than the Max. DOOR-LENGTH value displayed to the right of the key pad.Note: To clear a value press the CLR (clear) button.
64.75
7 8 9
4 5 6
1 2 3
0 DEC(.)
FRC(/)
DOOR-LENGTH
CLRKey Pad
Key PadDisplay
ClearButton
3.After the new value has been keyed in press the Enter key. This will load the keyed value into the “New” section of the display.
ENTER[DL-1]
64.75
7 8 9
DOOR-LENGTH 64.75 96.00 72.75110.75
NEW
4.Save or discard changes: 64.75 96.00 72.75110.75
PRESET
PREVIOUS MENU
Exit with
64.75 96.00 72.75110.75
DL-1DL-2DL-3DL-4
NEW
SAVE & EXITExit and
no Change Save New values
• Save and Exit will save the values displayed in the “New” section of the display as door width preset values.
• Previous Menu will exit leaving the “Preset” values as door width preset values.
Alliance Series - Rail 13-11
Entering Fractional Values:
For decimal mode enter the number using the Decimal Point key.
For fractional input enter the whole number then press the Fraction Key.
The Fractional Key displays the screen shown to the right. When a Fractional key is pressed the value is displayed is shown in thirty seconds of an inch. For example if 1/4 is pressed, 08/32 will be displayed.When the correct value has been entered press previous menu to return to the previous screen.
Feed Control
Toggles Auto Feed between ON and OFF.
Stack Control
STACK#2
STACK#1
Selects Stack #2 Selects Stack #1
LOAD POS
PICK-UP
Holding this button will
Holding this button will
raise the selected stack.
lower the selected stack.
DEC(.)
FRC(/)
[11/32] 42.34375
1/32 1/16 3/32 1/8 5/32 3/16 7/32 1/4
9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2
17/32 9/16 19/32 5/8 21/32 11/16 23/32 3/4
25/32 13/16 27/32 7/8 29/32 15/16 31/32
42
PREVIOUS MENU
Whole Number Fractional Number
AUTOFEED
13-12 Alliance Series
Touch Screen
• Stack Transfer (STACK XFER)
STACK XFER2 -> 1
The Stack Transfer button (STACK XFER) allows doors to be moved from Stack #2 to Stack #1.Unload Doors
Here
From Previous
STACK XFER2 -> 1
Remove DoorsHere
Remove Doors Here
STACK XFER2 -> 1
STACK XFER2 -> 1
Stack Transfer ONStack Transfer OFF
Machine
MAINTE-NANCE
page 13-18
GO TO REMOTE page 13-8
Navigation
• Go To Remote: Opens the Main Menu Remote screen. See page 13-8 for more information. • Maintenance: Opens the Maintenance screen. See page 13-18 for more information.
Ready Enter Data
READYENTRYDATA
Press this button to start the process after the door data, and the door have been entered into the machine.
Alliance Series - Rail 13-13
How to Run a Door in Manual Local Mode:
1.Load the door or doors into the machine.2.Select the Stack
STACK#1
STACK#2
3.Raise the stack to clamp-ing height.
PICK-UP
4.Select the door length. DOORLENGTH
5.Select the ModeSTACK XFER
2 -> 1
STACK XFER2 -> 1
Stack Transfer OFF
or
Stack Transfer ON
6.
READYENTRYDATA
Press Ready Enter-Data to start the process.
13-14 Alliance Series
Touch Screen
Manual Mode
PREVIOUS MENU
page 13-7
FORKLIFT SERVO
MANUALCROSSFEED-REV
CARRIAGE SERVO
102.28176
CLAMP
UP
UP
DOWNSTACK#1
LIFT
UP
DOWNSTACK#2
LIFT
STOP SERVO
123.45758
104.92365
DOWN
MANUALFEED-REV
IN OUT
#2 #1
RESETSEQUENCE
This screen give manual control to the operator.
Reset Sequence:
Use this button to return the ON-2010 back to a known state after any manual move.
Forklift Servo:
Holding this button will move the Forklift up.
Holding this button will move the Forklift down.
Stop Servo:
Holding this button will move the Stop toward the infeed end of the machine.
Holding this button will move the Stop toward the outfeed end of the machine.
RESETSEQUENCE
UP
DOWN
IN
OUT
Infeed End
Outfeed End
Stop
In
Out
Alliance Series - Rail 13-15
Carriage Servo:
Holding this button will move the Car-riage and Vacuum Clamp toward stack 2.
Holding this button will move the Car-riage and Vacuum Clamp toward stack 1.
Stack Control
Stack #2 Stack #1
Holding this button
Holding this button
will raise the stack.
will lower the stack.
UP
DOWNSTACK#1
LIFT
UP
DOWNSTACK#2
LIFT
• CLAMP UNCLAMP : This button toggles between, Clamp (Red) and Un-Clamp (Green).
When the button is Green the vacuum is applied to the Vacuum Clamp. When the button is Red, the Vacuum is removed from the Vacuum clamp.
Feed
• MANUALFEED-REV
Reverse Feed Direction
Reverse feeds the door on the roll table.
#2
#1
Infeed End
Outfeed End
Stack#2
Stack#1
13-16 Alliance Series
Touch Screen
• MANUALCROSSFEED-REV
Reverse Crossfeed Direction
Reverse feeds the door on the cross feed system.
Navigation:
• Previous Menu: Opens the previously opened screen.
Alliance Series - Rail 13-17
Maintenance -1
PREVIOUS MENU
page 13-8
FORKLIFTCHANGE
NEXT PAGE
page 13-19
MANUAL MODE
page 13-15
MODBUSMODE 172-SCN1_1v1
POSITIONCARRIAGECHANGEPOSITION
PLC
STOPCHANGEPOSITION
PLCINPUT-
OUTPUT
PLCTIMER
STATUS
PLCH-BIT
STATUS
SCRIPT& DRIVESTATUS
D1900-00D1900-01D1900-02D1900-03D1900-04D1900-05D1900-06
D1950.00D1950.01D1950.02D1950.03D1950.04D1950.05
Port-1MODE
D1900-11D1950.06
D1900-12D1950.07
D1900-13D1950.08
XX.XXX.X
XX.XXX.X
XX.XXX.X
MB STATUS[SERVO-PLC]
Machine Data
page 13-22
REMOVE DOOR
page 13-20
ModBus comm.
Touch Screen
Navigation
Status: Lift toLift to Rail
Programversion
Servo
ModBus
PositionPoints
Commmode
and Trouble-shooting
Servo Position Points:
• Forklift Change Position: Displays the Forklift Change Position menu. Parameters on this screen are factory set and should need no modification.
• Carriage Change Position: Displays the Carriage Change Position menu. Parameters on this screen are factory set and should need no modification.
• Stop Change Position: Displays the Stop Position menu. Parameters on this screen are factory set and should need no modification.
ModBus Communication mode:
MODBUSMODE
PROG.MODE
Normal Mode Program Mode
Toggles between normal and program mode. For normal operation this button must be in normal mode.
ModBus Communicating Status: Lift to Rail
Displays the status of the ModBus communication bits between the Lift PLC and the Galil motion control board. This display is designed to assist in trouble shooting the machine.
Touch Screen Program Version
This displays the program version loaded in the touchscreen. Have this number available when con-tacting KVAL for troubleshooting assistance.
13-18 Alliance Series
Touch Screen
PREVIOUS MENU
page 13-8
NEXT PAGE
page 13-19
MANUAL MODE
page 13-15
PLCINPUT-
OUTPUT
PLCTIMER
STATUS
PLCH-BIT
STATUS
SCRIPT& DRIVESTATUS
MB STATUS[SERVO-PLC]
Machine Data
page 13-22
REMOVE DOOR
page 13-20
Navigation
• Manual Mode: Opens the Manual Mode screen. See page 13-15 for more information. • Machine Data: Opens the Machine data screen. See page 13-22 for more information.• Remove Door: Opens the Remove door screen. See page 13-20 for more information.• Next Page: Opens the second maintenance page. See page 13-8 for more information.• Previous Menu: Opens the previously opened screen.
Troubleshooting
PREVIOUS MENU
page 13-8
NEXT PAGE
page 13-19
MANUAL MODE
page 13-15
PLCINPUT-
OUTPUT
PLCTIMER
STATUS
PLCH-BIT
STATUS
SCRIPT& DRIVESTATUS
MB STATUS[SERVO-PLC]
Machine Data
page 13-22
REMOVE DOOR
page 13-20
These buttons open the trouble shooting. Troubleshooting goes beyond the scope of this manual.
Maintenance -2
PREVIOUS MENU
page 13-18
12
12
CONTRAST LEVEL (0 - 31)
COLOR BRIGHT-NESS (0 - 31)
Touch Screen view adjustments:
• Color Brightness: Adjusts the touch screen’s brightness. • Contrast Level: Adjusts the touch screen’s contrast level.
Navigation:
• Previous Menu: Opens the previous screen.
Alliance Series - Rail 13-19
Remove Door
M-190M-191M-192M-193M-194
MANUALFEED
REVERSE
PREVIOUS MENU
page 13-19
NO ACCESS
STACK#1LOAD POS
PICK-UP
STACK#2LOAD POS
PICK-UP
RESETSEQUENCE
STACK#1
MANUALCROSSFEED
REVERSE
MANUALCROSSFEEDFORWARD
MANUALFEED
FORWARD
DOOR NOTIN POSITION
AUTOFEED
CLAMP
STACK#2
D1950-02D1950-04D1950.05D1950.06D1950.07D1950.08
D1950-00D1900-00D1900-02D1900-04D1900-05D1900-06
MB:OK
Feed
Homing Status andStart Button
Clamp: ManualOperation
Stack Control
ResetSequence
NavigationOpens Previous
Menu
Feed
•
Reverse Feed Direction
MANUALFEED
REVERSE
MANUALFEED
FORWARD
Reverse feeds the door on the roll table.
Forward feeds the door on the roll table.
Forward Feed Direction
Infeed End
Outfeed End
Feed Table.
ReverseCrossfeed
MANUALCROSSFEED
REVERSE
MANUALCROSSFEEDFORWARD
Reverse feeds the door on the roll table.
Forward feeds the door on the roll table.
Direction
ForwardCrossfeedDirection
Infeed End
Outfeed End
Cross feed system.
13-20 Alliance Series
Touch Screen
Clamp: Manual Operation
CLAMP CLAMPUN-
This button toggles between, Clamp (Red) and Un-Clamp (Green). When the button is Green the vacuum is applied to the Vacuum Clamp. When the button is Red, the Vacuum is removed from the Vacuum clamp.
Homing Status and Start Button
DOOR NOTIN POSITION
OK TO HOME HOMING ALL HOMEDHOMING
DISALBLEDXXXXX
The Homing Status and start button when pressed, starts the homing process. I also shows the current status of the homing process:
• OK to Home: The machine and door in the machine are in the correct position for homing.• Homing: Homing is in process.• All Homed: The homing process is finished.• Door Not in Position: The machine has detected a door on the cross feed system.
Note: In order to Home move the door into the End Mill section of the machine using the Manual Crossfeed Forward button on the touch screen. The door must contact the End Mill Door Stop. For more information see step 6. on page 13-14 under How to Manually remove uncompleted doors from the line:
• Homing Disabled: The machine is unable to home. The reason will also be stated.
Stack Control
STACK#2
STACK#1
Selects Stack #2 Selects Stack #1
LOAD POS
PICK-UP
Holding this button will
Holding this button will
raise the selected stack.
lower the selected stack.
Reset Sequence:
Use this button to return the ON-2010 back to a known state after any manual move. RESET
SEQUENCE
Alliance Series - Rail 13-21
Machine Data
MACHINE DATAMACHINE TOTAL
DAILY TOTAL
1,004,576
842
RESET PREVIOUS MENU
page 13-19DAILY
• Machine Total: Displays the count of completed milling cycles.• Daily Totals: Displays the total number of milling cycles completed since Reset Daily was pushed.• Reset: Resets Daily Totals to 0.• Previous Menu: Returns to the previous menu.
Technical Support
Previous Screen
page 13-19
TECHNICAL SUPPORT4:00 A.M to 4:30 P.M. (PACIFIC TIME)
MONDAY through FRIDAYPH: 800-553-5825
This screen displays KVAL’s support contact information. For more information visit www.kvalinc.com.
13-22 Alliance Series
Homing the RAIL
Homing the RAILThe Rail must go through a homing routing before any other operation is performed. Performing the homing routine establishes a home position - a zero-reference position from which the Rail measures its motion when making cuts.You should home the Rail:
• After powering up the system• After hitting the STOP then START buttons• When recovering from an Emergency Stop
To Home the Rail
The Rail machine has two sections, a door stacker and an end mill. Each section requires it’s own hom-ing routine.1.Homing the End Mill section of the Rail:
a. In the KVAL 2006 interface (on the PC), click on the Maint button. This will change the blank button below it to read Home.b. Click the Home button. This will change the button label to OK to Home?c.CLick the OK to Home? button.d.NOTE:While the homing operation is in progress, the Home button changes its label to Homing.
2.Homing the Door Stacker section of the Rail:a.On the touch screen Press OK to HOME.
Note: If there is a door in the Rail machine see step 6. under “How to Manually remove uncompleted doors from the line:” on page 1-16.
Maint
Home
OKHome?
Homing
O.K. TO HOME
Alliance Series 13-23
13-24 Alliance Series
CHAPTER 14 Calibrating the RAIL
Coming Soon
Alliance Series 14-1
Calibrating the RAIL
14-2 Alliance Series