endeavor door system - kval inc

Innovation, Quality & Honesty

Operation and Service Manual

Published: 8/10/2015

Endeavor Door System

Proprietary Notice

This Manual is confidential and contains proprietary information and intellectual property of KVAL Inc., and is to be used solely by Customer as an operating manual for KVAL Inc. machines. Neither this Manual nor any of the information contained herein may be reproduced or disclosed under any circumstances without the express written permission of KVAL Inc. For authorization to copy this information, please call Kval Customer Support at (800) 553-5825 or fax (707) 762-0485. Outside the U.S. and Canada, call (707) 762-7367.

Manual Part Number: 210_OPSRV_Endeavor_V1

The Endeavor is a trademark of Kval Incorporated.

Copyright 2015 Kval Incorporated. All rights reserved.

Beckhoff® , TwinCAT 2® , and EtherCat® are registered trademarks and are licensed by Beckhoff Automation GmbH

Windows 7® is a registered trademark of Microsoft Corporation .

All other products are trademarks or registered trademarks of their respective holders, all rights reserved. Reference to these products is not intended to imply affiliation with or sponsorship of Kval Incorporated.

Contacting KVAL

Customer Service: For further information about this manual or other Kval Incorpo-rated products, contact the Customer Support Department

• Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

• Phone and Fax:

In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Business hours:

Technical Support:

6:00 AM to 4:00 PM Pacific Standard Time, Monday through Thursday

6:30 AM to 1:30 PM Pacific Standard Time, Friday

Parts & Service Sales:



(Other sales related inquiries: http://www.kvalinc.com)

• Email: [email protected]

KVAL Endeavor Operation/Service Manual


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

http://www.kvalinc.com


Table of Contents

Chapter 1 Introduction to the EndeavorChapter 1 at a Glance ........................................................................................... 1-1

Overview of the Endeavor System ...................................................................... 1-2Endeavor Commercial Door Lock & Hinge Mortising Machine .................. 1-2Table of Available Options ............................................................................ 1-3About this Manual ......................................................................................... 1-4

Safety First!.......................................................................................................... 1-5Safety Sheet Sign-Off Sheet .......................................................................... 1-5Safety Terminology of Labels........................................................................ 1-5Safety Guidelines ........................................................................................... 1-5Lockout Tagout Procedure ............................................................................. 1-9Follow the P-R-O-P-E-R lockout rule of thumb.......................................... 1-11

Zero-Energy to Start-Up .................................................................................... 1-12Zero-Energy State to Start-Up to Operating State ....................................... 1-12

Getting Help from KVAL .................................................................................. 1-14On-Line Help ............................................................................................... 1-14Product Return Procedure ............................................................................ 1-14

How to Download the Service Application ....................................................... 1-16Download Application ................................................................................. 1-16

Safety Sign-Off Sheet ........................................................................................ 1-19A Note to the Operator: ............................................................................... 1-19

Chapter 2 Operation of the EndeavorOperator’s Tour .................................................................................................... 2-2

In-Feed Section .............................................................................................. 2-3Front Section.................................................................................................. 2-4Back Section: ............................................................................................... 2-10Out-Feed ...................................................................................................... 2-14About the Electrical Panels.......................................................................... 2-15Description of the Six Light Panel .............................................................. 2-16About Switches and Sensors ........................................................................ 2-17

Quick Start ......................................................................................................... 2-19

Powering Operations for the Endeavor.............................................................. 2-21How to Power Up the Endeavor .................................................................. 2-21Home the Machine ....................................................................................... 2-22How to Power Down the Machine............................................................... 2-22Emergency Shutdown and Recovery ........................................................... 2-23

2-1KVAL Endeavor Operation/Service Manual

Sequence of Operation ....................................................................................... 2-24

Description of the User Interface Screens ......................................................... 2-25

About the KvalShell User Interface ................................................................... 2-26Screen Selection Menu Map ........................................................................ 2-26About Machine Feed Back .......................................................................... 2-27About Preview Job ....................................................................................... 2-27About the Calibration Tab............................................................................ 2-28Main Control Screen .................................................................................... 2-28About the Predrill Tab ................................................................................. 2-32Predrill Template References ....................................................................... 2-34About Manual Servo Control Tab................................................................ 2-34 About the Status Screen .............................................................................. 2-35About the Log Screen .................................................................................. 2-36

KVAL 2015 User Interface Visual Tour ............................................................ 2-38Entering Data ............................................................................................... 2-38Structure, how the program thinks:.............................................................. 2-39

Door Files: Creation and Editing ....................................................................... 2-40Creating and Saving a Permanent Door File ............................................... 2-40Creating a New Permanent Door File .......................................................... 2-41Creating a Permanent Door File from an Existing Door File ...................... 2-42Modifying (Permanently) an Existing Door File ......................................... 2-43Merging Doors ............................................................................................. 2-45Creating Door Templates From Merged Doors ........................................... 2-45Deleting a Door File .................................................................................... 2-46

Chapter 3 Calibration of EndeavorChapter 3 at a Glance ........................................................................................... 3-1

About Calibration ................................................................................................ 3-2About the Calibration Menus and the Calibration Reference Cut ................. 3-2Before you Calibrate ...................................................................................... 3-2

About the Calibration Tab.................................................................................... 3-3Access to the Calibration Routines ................................................................ 3-3Unlock the Calibration................................................................................... 3-4Enter a Positive or Negative Number? .......................................................... 3-4How to Enter Calibration Data ...................................................................... 3-5About Restore Points ..................................................................................... 3-5

About the Door Feed Setup ................................................................................. 3-6About the Width and Door Feelers Adjustments ........................................... 3-6

About the Hinge Head Menu ............................................................................... 3-8About Head Axes Calibration........................................................................ 3-8About Chisels Calibration............................................................................ 3-10

2-2 KVAL Endeavor Operation/Service Manual

About Hinge Router and Predrill Calibrations ............................................ 3-10

About the Lock Head Calibration Menu............................................................ 3-12About Head Axes Calibrations (Lock Head) ............................................... 3-12About Chisel Calibrations (Lock Head) ...................................................... 3-13About Router and Bolt Drill Calibrations (Lock Head) .............................. 3-15About the Deep Mortise and Predrill (Lock Head)...................................... 3-16

About the Calibration Reference Cut................................................................. 3-18Hinge Head Reference Cuts......................................................................... 3-18Lock Head Reference Cuts .......................................................................... 3-18Start the Calibration Reference Cut ............................................................. 3-19

Chapter 4 System IT AdministrationSystem IT Administration.................................................................................... 4-2

About the Endeavor Computer ...................................................................... 4-2Connections on the PLC ................................................................................ 4-2Backing up the Computer .............................................................................. 4-3About Remote Connection to KVAL Service ................................................ 4-3

Chapter 5 Maintenance of the EndeavorMaintenance Schedule ......................................................................................... 5-2

Daily, Monthly, Six Month Maintenance....................................................... 5-2 Lubrication Schedule .................................................................................... 5-3

Lubrication Requirements.................................................................................... 5-4Linear Bearings, Flange Bearing, and Pillow Blocks .................................... 5-4Gear Motor Lubrication Requirements .......................................................... 5-5Ball Screws .................................................................................................... 5-5Description of Air Input System .................................................................... 5-5Adjusting the Air Line Lubricator ................................................................ 5-6Priming the Air Line Lubricator .................................................................... 5-6

About Replacing Bits........................................................................................... 5-7Location of Tools in the Carriages ................................................................ 5-7Tool Collet Wrench and Shaft Wrench List ................................................... 5-8How to Access to Bit Assemblies.................................................................. 5-9 Remove and Replace the Router or Pre-Drill Bits........................................ 5-9

Replacing the X-Axis Self Lubricator ............................................................... 5-12About the Automatic Lubricator.................................................................. 5-12

Chapter 6 Troubleshooting the EndeavorAbout Motion Control ......................................................................................... 6-2


Basic Control Circuit ..................................................................................... 6-2Typical Positioning Systems .......................................................................... 6-4

Troubleshooting Basics ....................................................................................... 6-7Before you Adjust .......................................................................................... 6-7Analyze the Sub Systems............................................................................... 6-8

Using Sensors to Trouble Shoot......................................................................... 6-10

Troubleshooting Electrical Problems................................................................. 6-11If the Power Stops During Normal Operation ............................................. 6-11Troubleshooting with the Status Light Panel .............................................. 6-12About VFD Troubleshooting ....................................................................... 6-17

Troubleshooting the Air Cylinders .................................................................... 6-18Adjusting Cylinder Extension Speed: .......................................................... 6-19Adjusting Cylinder Retraction Speed: ......................................................... 6-19

Network System Overview ................................................................................ 6-20Connections to Servo Drives ....................................................................... 6-20Connections to VFD’s (High Freq Panel).................................................... 6-20


Chapter 1 at a Glance

CHAPTER 1 Introduction to the Endeavor

This chapter provides an overview of the KVAL Endeavor System and important safety informa-tion to follow when operating the machine.


Section Name Summary Page

Overview of the System This section provides an overview of the Endeavor. It includes a general description and a table of available options

page 1-2

Safety First! IMPORTANT safety information is described in this section

page 1-5

Zero-Energy to Start-Up Procedure to power up your machine for the first time. page 1-12

Getting Help from KVAL This section describes the method to contact the KVAL service center for help. The section includes how to get information from the specification plate tor provide to KVAL, service center hours, and return procedures

page 1-14

How to Download the Service Application

Procedure to download an interactive application to allow Service Technicians to control your machine and help troubleshoot.

page 1-16

Safety Sign-Off Sheet A record to track operators that are trained on the machine.

page 1-19

1-1


Overview of the Endeavor System


Endeavor Commercial Door Lock & Hinge Mortising Machine

The Endeavor is a fully automatic computer controlled door machine capable of simultaneously routing both the lock stile and hinge stile. Corner squaring chisels are standard for hinge pockets and lock face plates. Pilot hole drilling is also standard for hinges, and is available as an option for lock face plates (See Table 1- 1).

Works In line with the Face

Machine orientation allows the Endeavor to work directly in line with the Kval Face: the lock side is fixed while the hinge side adjusts to match door width.

Automatic Door Specifications

Normally door specifications are automatically transferred to the machine’s computer just as a door enters from a Kval FACE, so no operator intervention is required. All functions are auto-matic including:

• adjustment for door thickness

• width and length

• door positioning

• setting head angle at 0 degree or 3 degree

• clamping

• detection of exact door top location on both lock stile and hinge stile.

• The automatic cycle includes all machining operations, followed by unclamp and out-feed.

About the Lock Side

For the lock side, the machining carriage features three heavy duty three phase spindle routers: a 12HP motor for mortise lock and cylinder bores, and two 7-1/2 HP motors, with one motor with left had rotation and the second motor with right hand rotation to process hardware templates requiring routing through the top or bottom door faces – such as T strikes, or through the stile end for an auto flush bolt. The entire head pivots from zero to three degrees on precision Timken bear-ings as part of the automatic sequence.

The lock carriage X axis travel is 122", the Y axis travel is 20.0" and Z axis travel is 9-1/2''. Feed speeds up to 2400 inches per minute can be programmed. This 'X' axis travel allows the head to machine the full length of the lock stile for top and bottom flush bolts or multi-point lock hard-ware on a 10'-0'' door.

About the Hinge Side

For hinge side machining, two additional independent carriages simultaneously process hinge mortises while the lock is being detailed. Each carriage includes two heavy duty 3 HP 3 phase high frequency motors which also pivot either for 0 or 3 degree bevel, again with precision Tim-ken bearings. One motor is right hand rotation and the second motor is left hand rotation. The computer automatically selects the proper motor to cut into the door to eliminate chip-out and


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then switches to the second motor to prevent chip-out at the other end of the hinge. Programming is available for SOSS hinges and intermediate pivots.

Each hinge routing carriage also includes a pre-drilling motor for hinge screws and corner squar-ing chisels for square hinges. The pre-drill motor on each carriage is a high frequency 23,000 RPM spindle equipped with a quick change chuck. Programmed drill motion processes pilot holes in succession for a variety of hinge sizes. The corner squaring chisels can be selected to automati-cally square the corners of hinge pockets machined with a 1/2'' router bit.

Almost any combination of hinge spacing can be easily programmed with both carriages simulta-neously machining two hinge pockets and automatically machining the third pocket, or fourth pocket, in a second operation. Typical overall cycle time for doors with four hinges, squared and drilled for screws, and including lock detailing for either a cylinder or mortise lock will be under sixty seconds door to door. The cycle will be slightly higher when door width changes, and up to twice as long for doors with a T strike combined with a top and bottom flush bolt.

Table of Available Options

Option Title Description

Option A Point to Point Pre-Drill for Lock Machining Carriage

Single 23,000 RPM spindle drill unit with quick change chuck. Programmed motion drills pilot holes in succession for hinge or lock face plate screws.

Option LC Laser Calibration for Tooling After homing the machine each cutting head automatically moves to a laser calibration station to measure tool diameter and position of end of tool. Three calibration stations are provided one for each machining head. Eliminates the need for the opera-tor to make test cuts, measure the location and depth, manually enter the corrections and to make a second cut to verify correc-tions.

Option Tooling and Lubricant Package Please review with your KVAL consultant to determine your needs.

Option Spare Parts Package Please review with your KVAL consultant to determine your needs.

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About this Manual

This manual contains operation information and service and maintenance information.

It includes identification of machine assemblies, power-up and power-down steps, and informa-tion about using the user interface.

The Troubleshooting and Maintenance sections are directed toward qualified service technicians

TABLE 1- 1.

Title Part Number

Endeavor Operation and Service Manual 210_OPSRVDOC_Endavor


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Safety First!

Safety First!

Safety Sheet Sign-Off Sheet

At the end of this chapter, there is a safety sign-off sheet. It lists personnel and machine safety cri-teria to understand before operating the machine. It is highly recommended that personnel operat-ing, working on a machine meet the criteria listed in this sheet. It is recommended the sheet be signed and kept for records. See “Safety Sign-Off Sheet” on page 1-19.

Safety Terminology of Labels

In addition to the nameplate, KVAL machines may have other warning labels or decals that pro-vide safety information to operators. Safety labels should be clearly visible to the operator and must be replaced if missing, damaged, or illegible.

There are three types of warning labels or decals:

• DANGER means if the danger is not avoided, it will cause death or serious injury.

• WARNING means if the warning is not heeded, it can cause death or seriousinjury.

• CAUTION means if the precaution is not taken, it may cause minor or moderateinjury.

Safety Guidelines

In addition to the caution and warning labels affixed to this machine, follow the guidelines below to help ensure the safety of equipment and personnel.

This machine is a powerful electro-mechanical motion control system. You should test your motion system for safety under all potential conditions. Failure to do so can result in dam-age to equipment and/or serious injury to personnel.

Ensure that all employees who operate this machine are aware of and adhere to all safety precautions posted on the machine and are trained to operate this machine in a safe manner.

Training

1-5


Safety First!

Never operate the machine without proper eye and ear protection.

Protective Gear

• Never reach hands beyond safety cage. Servo motors can unexpectedly move quickly.

• Never clear screws or hinges out of the machine while it is running.

• Never reach into the router area to retrieve a hinge. The router may still be running down after shut down.

• Never perform any maintenance unless machine is at zero state.

• Never clean the machine while it is running.

• Never walk away from the machine while it is running.

When the Machine is ON

The compressed air system connected to this machine should have a three-way air valve for shut-off and pressure relief.

All cylinders on machine are under high pressure and can be very dangerous when activated. Before performing any mainte-nance or repairs on this machine turn off the main air disconnect. Lockout and tagout this connection.

See “Lockout Tagout Procedure” on page 1-9.

Compressed Air


1-6

Safety First!

Electrical circuitry on this machine is protected by an approved lockable disconnect circuit. In addition to this equip-ment, you must install an approved disconnect for the electrical power supplying this machine.

When opening the cabinet you must first turn off the disconnect switch. When the cabinet door is open there is still power on the top side of the disconnect switch. Some machines are powered by more than one supply located at different locations. Before performing any repairs or mainte-nance, lockout and tagout must be installed at all locations

All maintenance and repairs to electrical circuitry should only be per-formed by a qualified electrician.

Still has powerin OFF position

Electrical

Prior to performing any maintenance, repairs, cleaning or when clearing jammed debris, you must disconnect, tag out, or lock out the elec-trical and air pressure systems. This should be done in accordance with applicable state and/or federal code requirements.

Before Conducting Maintenance

1-7


Safety First!

Follow Your Company’s Safety Procedures

In addition to these safety guidelines. Your company should have on-site and machine specific safety proce-dures to follow.

KVAL advises that you request an on-site state safety review of your installation of this machine. This is to ensure conformance to any additional specific safety and health regula-tions which apply in your geographic area.

Compliance with Codes and Regulations

Other Hazard Control Action

Report a Hazard Before You Report an Accident

If you believe any part or operation of this machine is in violation of any health or safety regulation, STOP pro-duction. It is your responsibility to immediately protect your employees against any such hazard.

Additional detailed safety guidelines are included in the operating instructions of this manual. KVAL will be pleased to review with you any questions you may have regarding the safe operation of this machine


1-8

Safety First!

Lockout Tagout Procedure

This policy is required by OSHA regulation 1910.147 and Cal OSHA’S SB198 ruling of July 1991.

Use the following lockout procedure to secure this machine while it is powered down. During a lockout, you disconnect all power and shut off the air supply. Be sure to use the tagout guidelines noted below.

To Lockout the This Machine

1. Assess the equipment to fully understand all energy sources (multiple electrical sup-plies, air supply and pressure, spring tension, weight shifts, etc.).

2. Inform all affected personnel of the eminent shutdown, and the duration of the shut-down.

3. Obtain locks, keys, and tags from your employer’s lockout center.

4. Disconnect power:

a.Turn the disconnect switches on the main electrical panel to the OFF position. Then pull out the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tagout guidelines below. (see illustration below).

When multiple people are working on the machine, each person needs to have a lock on the handle in the extra holes provided.

b.Turn the disconnect switch on the larger high-frequency panel to the OFF position. Then pull out the red tab and place a padlock through the hole. Place your tag on the padlock, as per the tagout guidelines below.

1-9


Safety First!

5. Turn the main air valve to the OFF position and place a padlock through the hole (see illustration below).

NOTE: Place your tag on the padlock, as per the tagout guidelines below.

6. Once the locks and tags are in place and all personnel are clear, attempt to operate the machine to ensure equipment will not operate.

7. Maintenance or repairs may now be completed. The person performing the work must ensure all tools, spare parts, test equipment, etc., are completely removed and that all guards and safety devices are installed.

8. Before removing the locks and tags, the person who attached them shall inspect the equipment to ensure that the machine will not be put in an unsafe condition when re-energized.

9. The lock and tag can now be removed (only by the person(s) who placed them), and the machine can be re-energized.

10. The tags must be destroyed and the locks and keys returned to the lockout center.

Lockout-Tagout Guidelines

• Place a tag on all padlocks. On a tag, each operator must put their own name and date. (These locks are only to be removed by the person who signs the tag)

• If more than one person is working on the machine, then each additional person places a lock and tag on each disconnect.

• Only each operator may remove their own lock and tag.


1-10

Safety First!

Important: When many people are all working on the same machine you will need a multiple lockout device, such as the one shown here.

Follow the P-R-O-P-E-R lockout rule of thumb.

P...... Process shutdown

R ...... Recognize energy type (electrical, pneumatic, mechanical, etc.)

O...... OFF! Shut off all power sources and isolating devices

P...... Place lock and tag

E...... ENERGY: Release stored energy to a zero-energy state

R ...... Recheck controls and test to ensure they are in the “OFF” state

1-11


Zero-Energy to Start-Up


Zero-Energy State to Start-Up to Operating State

Starting the equipment properly is just as important as the lockout/tagout guidelines in terms of safety.

Start-up Guidelines

The following guidelines below should be followed to start the equipment.

Inspect

The equipment must be inspected for proper adjustment before starting equipment.

Clean Up

All materials and debris must be cleaned up. Any combustible materials or old parts used during repairs must be cleaned up and/or properly disposed of.

Replace Guards

Replace all equipment guards. If part of equipment cannot be properly adjusted after start-up with guard on, contact the KVAL Service team. See “Getting Help from KVAL” on page 1-14.

Check Controls

Confirm that all switches are in the “OFF” position. Please be advised that some com-ponents of the machine may start automatically when energy is restored.

Remove Locks

Each operator must remove his or her own lock and tag. This will ensure that all oper-ators are in a safe place when the equipment is started.

Perform Visual Checks

If the equipment is too large to see all around it, station personnel around the area and sound the personnel alarm before starting the equipment. If your operation is more complex, your company’s comprehensive safety procedure may involve additional steps. You will need to ask your supervisor about these procedures. The company’s lockout procedure should be posted at each machine. On larger or long-term mainte-nance or installation projects, the company’s procedures must be explained to all new operators and a copy of the company’s procedures should be posted on-site for the duration of the work.

The Company’s procedures should also include provisions for safely handling shift changes and changes in operators or new operators.Comprehensive lockout/tagout


1-12


may use a gang box or other system to ensure that locks are secure and not removed without authorization.

Remember, lockout/tagout procedures work because you are the only one with the key to your lock. Proper lockout/tagout can save lives, limbs, and money. Help make your work environment safe for you and your fellow workers. Be sure to follow the P-R-O-P-E-R lockout/tagout procedures, and that those around you do also.

Close the Cage Gate

Verify all cage gates are securely closed. Ensure all safety protocols are in effect.

1-13


Getting Help from KVAL


Before you seek help, first try the troubleshooting procedures. Follow the procedures below.

If you are unable to resolve the problem:

1. Locate the machine’s Specification Plate and record the serial number, 3 phase volts, electrical print number, and air print number.

Serial Number

3 phase volts

Electrical Print

Air Print

2. Contact our customer support team:

• In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

• Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

• Email address is [email protected]

• Hours:



On-Line Help

On machines with a Beckhoff® PLC and an internet connection, our service team are able to con-nect, run, and troubleshoot your machine. Ask about this procedure when calling are service team.See Chapter 3 “System IT Administration” on page 4-1, for more information.

Product Return Procedure

If you’ve contacted Kval for help and it is determined that a return is necessary, use the procedure below to return the machine or part.

Note: Non-Warranty returns are subject to a 15% restocking charge.

1. Obtain the packing slip and/or invoice numbers of the defective unit, and secure a purchase order number to cover repair costs in the event the unit is determined to be out of warranty.


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2. Reason for return: Before you return the unit, have someone from your organization with a technical understanding of the machine and its application include answers to the following questions:

• What is the extent of the failure/reason for return? What are the relevant error mes-sages or error codes?

• How long did it operate?

• Did any other items fail at the same time?

• What was happening when the unit failed (e.g., installing the unit, cycling power, starting other equipment, etc.)?

• How was the product configured (in detail)?

• Which, if any, cables were modified and how?

• With what equipment is the unit interfaced?

• What was the application?

• What was the system environment (temperature, spacing, contaminants, etc.)?

3. Call Kval customer support for a Return Material Authorization (RMA). When you call:

• Have the packing slip or invoice numbers available.

• Have the documented reason for return available.

4. Send the merchandise back to Kval.

• Make sure the item(s) you are returning are securely packaged and well protected from shipping damage

• Include the packing slip or invoice numbers.

• Include the documented reason for return.

• Include the RMA number with the parts package.

1-15




On machines with Windows (8.1 / 8 / 7 / Vista / XP) and an internet connection, our service team are able to connect, run, and troubleshoot your machine by way of the operator station.

Download Application

.1. To download the application, go

the KVAL website (http://

www.kvalinc.com)

2. At the KVAL website, select the Support tab. Follow the instruc-tions on the Support web page.

3. Click the Download button to download the application that allows the KVAL technician to have access to the operator sta-tion.

4. After the download is com-pleted, double-click the program icon.

Note: Web browsers have different methods of downloading programs. Below are samples of i.e Explorer and Google web browsers.

Sample of Google Browser: Located at the bottom left of the screen.

Sample of i.e Explorer: Located at the bottom of the screen. select the arrow and choose Save and Run


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5. A pop-up window is displayed. Accept the request to run the program.

Note: Security settings may differ from plant to plant. If issues occur, con-tact your IT department.

6. The interface of the KVAL Support App will be dis-played. Enter your name in the Your Name field. The fields are described below:

Session code: An internal number to track this machine. It is auto filled.

Allow Remote Control: Program is ready to allow technicians to access machine computer

Your Name Field: Enter your name. The KVAL tech-nician will use this field to identify this machine.

Description: Enter machine Serial number and issue.

Indicator: Green indicates there is a good connec-tion to the service center. If red, there could be an issue with a LAN connection. Check the connections in the plant.

7. After the KVAL Support App is loaded and completed, call the KVAL service center(1-800-553-5825) and have the technician con-nect to the machine computer.

8. Click the Allow button to give the KVAL service technician permis-sion to access the operator station.

We are now ready to troubleshoot.

1-17



Page Intentionally Left Blank


1-18

Safety Sign-Off Sheet


Machine Model Number:_____________________________

A Note to the Operator:

This machine can help you be highly productive only if you understand how to use it properly and follow the safe operating practices described in this document and the machine’s manual. If you do not understand the machine’s proper operation or ignore the safe operating practices, this machine can hurt or kill you. It’s in your best interest to safely and properly operate this machine.

Personnel Safety Concerns:

• I have been properly trained in the operation of this machine.

• I will always wear ear protection when operating this machine.

• I will always wear eye protection when operating this machine.

• I will never wear loose clothing or gloves when operating this machine.

• I will watch out for other people. Make sure everyone is clear of this machine before operation.

• I will always follow my company’s safety procedures. I have read and understand these guidelines.

Machine Safety Concerns:

• I have been given a tour of the machine and understand all the safety labels, E-Stops and the actions to take in case of an emergency.

• I will make sure all guards are in place before operation

• I will turn off the compressed air, before loading hardware (staples, screws, etc)

• I will turn off the electrical power, for setup

• If the machine should operate in an unexpected manner stop production I will immediately and notify a manager, a supervisor, or a qualified service technician.

I have read and understand this document and agree to operate this machine in a safe man-ner as described above.

Employee

Name (print):___________________ Signature: __________________ Date:____/____/____

Supervisor/Safety Officer/Trainer

Name (print):__________________Signature: __________________ Date:____/____/___

Note: It is recommended you make a copy of this sheet for new operators. If a copy is needed, you may download a PDF at the KVAL website (http://www.kvalinc.com). You may also contact our Service Department at (800) 553-5825 or email at [email protected].

1-19




1-20

CHAPTER 2 Operation of the Endeavor

This chapter describes components, assemblies, and the user interface of the KVAL Endeavor Sys-tem. The content is geared to help operators understand the basic operation of the machine. Included are instructions to calibrate the machine and process a door.



Operator’s Tour Descriptions of the parts and assemblies of the machine. Includes the In-Feed, Back Section, Front Section, Out-Feed and Electrical Panels.

page 2-2

Quick Start A summary of the steps to machine a door. page 2-21

Powering Operations for the Endeavor

Descriptions of power up, power down, homing, and emergency stops

page 2-23

Sequence of Operation A list of the order in which the machine processes a door.

page 2-26

Description of the User Interface Screens

An introduction to the Kval User Interface and the Kval2015 user interface.

page 2-27

About the Kval User Interface

Descriptions of the setup screens in the KvalShell inter-face. Included is descriptions of the tabs and the opera-tions they control.

page 2-28

About the Kval2015 User Interface

A tour of the KVAL 2015 Interface. Included is creation, editing, and deletion of door files.

page 2-40

2-1


Operator’s Tour

Operator’s TourThis section takes you on a tour of the Endeavor Door Processing machine.

Electrical Panels: 2 Main Panels

1 VFD Panel

Cable Track

See “About the Electrical Pan-els” on page 2-15

Operator Station

See “Operators Station” on page 2-6

Back Section:

Stationary Fence

Lock Carriage

• Router

• Counter Rotate Router

• Mortise Router

• Opt A: Predrill or Opt: Deep Drill

• Chisels (X4)

• Pushover with Encoder

See “Back Section:” on page 2-10

Front Section:

Movable Fence

2 Independent Carriages

• Pre Drill

• Counter Rotate

• Router

• Chisels (x2)

• Pushover with Encoder

See “Front Section” on page 2-5

In-Feed

See “In-Feed Section” on page 2-3

Out-Feed

See “Out-Feed” on page 2-14

Hinge Carriage

FIGURE2- 1. Identification of Key Assemblies of Endeavor


2-2

Operator’s Tour

In-Feed Section

• Door is input from previous machine

• Feedback to Machine computer, of actual door width, length, and thickness.

Note: (Thickness feedback is an option)

• Door is feed through machine for processing

• The door is automatically positioned and clamped.

In-Feed System: Door Enters Machine here. Sensors triggered and width is adjusted to door

Width Adjust Motor: Drives the movable fence to the width of the door.

Door Length Feelers: Senses the actual length of the door and feeds it back to machine computer.

Sensors: As door enters machine, sensors trigger feed operation.

See “About the Door Length Feelers” on page 2-4.

Door Stops: Door Feeds into Stop. Firstsensor to measure door length.

FIGURE2- 2. Key Assemblies on the In-Feed Section

2-3


Operator’s Tour

About the Door Stops

The door feeds in to rest against the Door Stops. The Door Stops provide a physical reference for the bottom of the door. Each Stop also has an encoder to start the length measurement of the door. The data from the Stop encoders combine the Door Feeler encoders to feed back to the machine computer to calculate the true length of the door.

About the Door Length Feelers

The Door Length Feelers are part of the process to sense the length of the door. After the door has been fed in to the door stop the feelers “feel’ the other end of the door. The measurement of the stop and the feeder encoders are combine to calculate the exact length of the door.

.

FIGURE2- 3. Door Feelers Assemblies

Fixed Fence (Back Section) Movable Fence (Front section)

1. The door is fed to the Door Stops where and encoders collects door length data.

2. The Door Feelers go to the top edge of the door and encoders collects data

3. The data is sent to the machine computer and the length is calculated.


2-4

Operator’s Tour

Front Section

The Front Section contains:

• Operator Station, gives the user control of the process.

• Front Section Door Clamps.

• Signal Light

• Hinge Carriages 1 and 2, perform all the drilling and routing on the door hinge side.

FIGURE2- 4. Front Section View

Hinge Carriage

Hinge Carriages

See “Hinge Carriage” on page 2-8

Hinge Carriage

Operator Station


Out -FeedIn-Feed

Door Clamps

See “About the Door Clamps” on page 2-7

Carriage Rails

See “About the Carriage Rails and Auto Lubrica-

tor” on page 2-9

Signal Light


Door Thickness Feelers

2-5


Operator’s Tour

Operators Station

The Operator Station contains a touch screen that allows communication between the operator and the machine. setup, thereby saving time. Depending on the option ordered, some Operator Stations may have multiple machine controls. For example, Figure 2- 5 below shows an Operator Station that contains a Feeder, Face SS, and the Endeavor controls.

FIGURE2- 5. Example of an Operators Station with Touch Screen Interface

LCD Touchscreen Interface with access to the Control Software

Endeavor Start-Up and Shutdown Controls

Endeavor Opera-tor’s Keyboard.

See “Powering Opera-tions for the Endeavor”

on page 2-23.

See “Screen Selection Menu Map” on page 2-28.

Some options add other Machine Con-trols at the Station


2-6

Operator’s Tour

About the Door Clamps

Door clamps on the fixed fence and the movable fence secure the door for machining

FIGURE2- 6. Door Clamps

1.

2.4. The Kval User Interface calibrates, manual

adjusts, sets pre-drill and lock plate parame-ters, and provides feedback about machine status.

5. The KVAL 2015 software program defines and executes door files which contains the specifications for the cuts the machine makes to the doors.

About the User Interface Software

See “Screen Selection Menu Map” on page 2-28 .

The Endeavor interface has two software programs to control the machine

Door Clamps are located on the back and front fences

Note: Door Clamps on the Lock side will retract over a Mortise cut and clamp when finished.

2-7


Operator’s Tour

Hinge Carriage

There are 2 Hinge Carriages on the front section. Each carriage includes:

• A router to automatically rout a hinge pocket on the door.

• A counter rotate router to provide smooth non-splinter cuts.

• A drill to drill pilot holes in the hinge pockets.

• Chisels to square-off the corners of the hinge pocket.

• A push over assembly with an encoder to push the door snuggly against fixed fence and provide measurement feedback to PLC.

• A zero and three degree cylinder to position the carriage.

• Servo controlled in X, Y and Z.

• E-Stop (Emergency Stop)

Tool View of the Hinge Carriage

FIGURE2- 7. Hinge Carriage Parts

Pre-Drill: Drills pilot holes for insertion of screws on the door

Hinge Router: Routs the hinge pocket

Chisels: Four chisels the corner edges of the hinge pocket to cre-ate a square hinge

Assist Cylinders: Assists carriage move vertically in the up and down motion.

Counter Rotate Hinge Router: Routs the hinge pocket providing a clean cut.

Push Over/Encoder: Pushes the door to the back fence. Encoder measures distance for feedback to PLC.

“Y” axis Servo Motor

Cylinders:

Chisels (X4)

Pre-Drill

Hinge Router

CR Router

Push Over

Zero/Three Degree

“Z” axis Servo Motor


2-8

Operator’s Tour

Back View of the Hinge Carriage

FIGURE2- 8. Rear View of Carriage

About the Carriage Rails and Auto Lubricator

FIGURE2- 9. Auto Lubricator

Valve Bank: Con-trols Chisels, Routers, predrill, and push-over Cylinders:

Chisels (X4)

Pre-Drill

Hinge Router

CR Router

Push Over

Zero/Three Degree

E-Stop: Emer-gency Stop

The carriage motor gears and rails on the front and back section are lubricated by an auto lubricator. When empty, the lubrica-tor is replaced as a unit. A message is sent to the User Interface when the lubricator needs to be changed. Change the module at that time.

The Auto Lubricators are located opposite the tool side of each Hinge Carriage and the Lock Head Carriage. See “Replacing the X-Axis Self Lubricator” on page 5-12

Auto Lubricator and Carriage Rails

X Axis Servo Motor

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Operator’s Tour

Back Section:

• Works in partnership with front section process

• Includes faceplate routing

• Option A: Contains Function Drill motor to drill pilot holes for handle lock.

• Contains Servo motors for X, Y, and Z

FIGURE2- 10. Back Section View

Lock Head Carriage

There are Lock Head Carriage is located on the back section. The carriage includes:

• A router to automatically rout the face plate.

• Chisels X4 to square the corner of the Lock Plate

• A counter rotate router to provide smooth non-splinter cuts.

• A pre-drill drills pilot holes in the hinge pockets. (Opt A) or a deep drill for 8 inch lock holes (Opt)

• A Plunge Router to drill the lock hole.

• A Deep Mortise Router to router deep pockets.

Pop Up Fence

See “About the Back Fence.” on page 2-13

Door Clamps

See “About the Door Clamps” on page 2-7

Carriage Rails

See “About the Carriage Rails and Auto Lubrica-

tor” on page 2-9

Lock Head Carriage

See “About the Carriage Rails and Auto Lubricator” on page 2-9

Feed Motors: Drives the belt system to feed the door out


2-10

Operator’s Tour

• A push over assembly and an encoder to measure width of door.

• A zero and three degree cylinder to position the carriage.

• Servo controlled in X, Y and Z.

• E-Stop (Emergency Stop)

Tool Side View of Lock Head Carriage

FIGURE2- 11. Lock Carriage (Tool Side View)

Pre-Drill (Option A): Drills pilot holes for insertion of screws on the door or (Opt) Long Drill

Plunge Router: Routs the lock hole in the door

Assist Cylinders: Assists the lock carriage move vertically in the up and down motion.

Counter Rotate Router: Routs the pocket providing a clean cut.

Zero/Three Degree Cylinder: Moves the carriage to 0 and 3 degree positions

“Y” axis Servo Motor

Cylinders:

Pre-Drill (Opt) or Deep Drill (Opt)

Face Plate Router

Plunge Router

CR Router

Deep Mortise Router

E Stop: Emergency Stop

Face Plate Router: Routs the Face plate pocket

Deep Mortise Router: Routs a deep pocket.

“Z” Axis Servo Motor

“X” Axis Servo Motor

Push Over/Encoder: Pushes the door. Encoder measures dis-tance for feedback to PLC. (see inset)

Lock Head Push Over

Encoder:

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Operator’s Tour

FIGURE2- 12.

Cylinders:

Pre-Drill (Opt)

Face Plate Router

Plunge Router

CR Router

Deep Mortise Router

X Axis Servo Motor: Drives head along the X axis

Auto Lubricators: Auto lubri-cates the X-Axis Gear and rail. See “Replacing the X-Axis Self Lubricator” on page 5-12

Lock Head Node: Contains electrical connections for lock head

Valve Bank:

Chisels: Contains 4 chisels to square off lock plate corners.


2-12

Operator’s Tour

About the Signal Light

The Signal Light indicates the status of the machine. This is used for noisy environ-ments and a quick way to see the status of the machine. The Signal Light is located on top of the Lock Head. Below are color and status noninterferences.

FIGURE2- 13. Signal Light

About the Back Fence.

TABLE 2- 1.

Color Signal Status

Flashing Green Machine is ready to run, waiting for program download

Solid Green Machine is processing a task

Flashing Yellow Not Retracting Tools

Yellow Oiler is Low

Flashing Red Machine is preparing for next task

Red External Carriage Motor overload

Flashing Blue Servo Position Error

Signal Light: Located on top of Lock Carriage

The Pop-up Back Fence initiates as soon as the auto feed is turned on. The Door is fed to the stops.The Door pusher on the Hinge Heads pushes the door against it. The Hinge encoder takes a measurement. The door pusher on the lock side pushes against the door and the encoder takes a measure-ment. The Clamps activate the Back Fence retracts.

2-13


Operator’s Tour

FIGURE2- 14. Pop up Back Fence

Out-Feed

• The door is automatically positioned to be fed into the next machine.

• After the door machining is completed, the door is automatically (or in some cases manually) fed to the next machine.

FIGURE2- 15. Key Assemblies on the Out-Feed Section

Feed Motors: Drives the belt system to feed the door out

Out Feed: Door is fed to next stage.

Air System and Valve Bank: Air system deliv-ers CDA and lubricated air to valve banks and air cylinders, The valve bank: door stops and air blow off,


2-14

Operator’s Tour

About the Electrical Panels

The Endeavor has two Main Electrical Panel and a High Frequency Panel. Figure 2- 16 below, is an overview of the location of assemblies in the panels

The Main Electrical Panels:

• Supplies voltages to the machine

• Contains the PLC (Programmable Logic Controller)

• Contains servo drives to interact with the servo motors in the machine.

The High Frequency Panel

• Supplies voltages to the machine

• Contains the PLC interface

• VFDs (Variable Frequency Drives) to interact with hinge and faceplate rout-ers, width adjust motors, and feed motors.

Warning: High Voltage is present in this panel at the top of the Three Phase Input even with the disconnect off. If working on the panel, follow the safety protocol as described in Chapter 1.

.

FIGURE2- 16. Overview of Main Electrical Panels

Main Electrical Panel #1 Main Electrical Panel #2 Cooling

Fan Cooling Fan

24 VDC PS 24 VDC PS

High Voltage Input and

Fuses

Servo Drives

6-9Servo Drives

1-5

High Voltage Input and

Fuses

PLC with inputs out-

puts and volt-age terminals

Voltage terminals

Transformer and fuses

2-15


Operator’s Tour

FIGURE2- 17. High Frequency Panel

Description of the Six Light Panel

The six lights on this panel indicate the status of the Endeavor system.

The Sequence that the lights activate is as follows:1. Control Power

2. Overload Relay

3. E-Stop

4. Stop

5. Start

6. 24VDC

High Frequency Panel

PLC Interface Terminal

110 V / 24 V Terminals

High Voltage Section

VFD Section

Controls Motors:

• Hinge Routers

• Hinge Counter Rotate Routers

• Hinge Pre-Drills

• Feeder Movable

• Lock Standard Routers

• Lock Counter Rotate Routers

• Lock Short Router

• Lock Deep Mortise

• Lock Pre-Drill (Opt) or Lock Deep Drill (Opt)

Cooling Fan


2-16

Operator’s Tour

About Switches and Sensors

On the 990-F4, sensors and limit switches provide input to the PLC as part of the automation of the door cutting process. Inputs can include feed through, door clamping, door location, and limits of movement of machine assemblies.

Sensors are electronically tripped while limit switches are mechanically tripped. It is important to keep the sensors cleaned and aligned to keep the door process running smoothly. There are two classifications of sensors: Photo Electronic and Inductive Proximity Sensor.

Control Power – light illuminates when the Control Transformer is pulled out and the power is working on secondary side-of transformer

Overload Relay – The overload circuit is working when light is on

E-Stop – The back gate is closed and Frame E-stop is not acti-vated when this light is on.

24VDC – light comes on once the

ACR is latch and the 24VDC power Supply is working

Stop – This light will be on if Machine Stop button is deac-tivated.

Start – This light will be on once the Machine Start button is pressed and the ACR Relay is latched.

2-17


Operator’s Tour

.The Limit Switch is activated by an assembly moving a switch arm.

• .Depending on the model of limit switch, the amount of “pre-travel” (amount of movement from the arms resting position) is either 5 or 20 degrees before the limit switch actuates (Clicks).

Switch Arm

The Photo Electronic Detector uses light as a trigger.

• Photo Eye Detectors contain both emitter and receiver.If an object is within the Photo Eye’s sensing field light from the emitter is reflected from the object back to the receiver. With no object is in front of the Photo Eye a constant 24VDC is sent to the PLC. If an object is sensed by the Photo Eye, 0VDC is sent to the PLC.

• As a result, any of the photo detectors output equals 0VDC when a door is sensed.

• Some detectors have an emitter and receiver built in one unit, such as an in-feed sensor where a door blocks the light and reflects back to the unit.

• Some detectors have an emitter and receiver built in separate units, such as the through beam sensor set at a distance from each other. If an assembly is in between the two sensors the machine will not operate.

One Package

The Proximity Sensor detects metallic objects without touching them.

• An inductive proximity sensor consists of a coil and ferrite core arrangement, an oscillator and detector circuit, and a solid-state output. The ferrite core and oscillator create a field generating out the front of the sensor. When a metal object enters the field, a loss in amplitude occurs. The detector circuit recognizes the loss of amplitude and generates 0VDC to send to the PLC. When the metal object leaves the sensing area, the sensor to returns to 24VDC and sends it to the PLC.

• As a result, if a metal object is sensed, the output of the sensor equals 0VDC

Sensors on Piston and Cylinder


2-18

About Machine Line

About Machine Line

From one screen the entire machining process can be observed. This screen adds the ability to see where the door is in the process or where it might be stopped. In summary, at the Machine Line Screen:

• A summary of the status of the machines can be observed.

• Upcoming and in-process door jobs can be observed

• Machines can be Paused individually

• Jobs can be Aborted

• The entire line can be Reset.

Quantity:

The number of Doors selected from the Template

State

Idle – Machine is not paused and has no active job runningPaused – Machine is paused and has no active job running

Preprocessing – Machine is feeding the door in, measuring, and clamping, no cutting has occurred yet

Processing – Machine is running cuts on the doorPostprocessing – Machine has finished running cuts on the door and is unclamping and feeding the door out of the machine

JobName:

The name of the selected template.

2-19


About Machine Line

Machine Activity

The color of the background shows the activity of the machine.

• Green: Actively working on a door

• Orange: Machine is Paused

• White: Idle

Commands:

• Ignore Job: Sets the job to be ignored, only possible by aborting an active job first, an ignored job will be ignored by all machines in the line after being set to ignore

• Pause: Puts the machine in a pause state, if the machine is currently processing the door it will continue processing the door but not accept any new doors until resumed

• Abort: Halts any active door job and puts the machine into pause state, from here the job can be set to be ignored. Un-pausing the machine after an abort will cause the machine to rerun the last door job it was doing unless the job was set to be ignored

Reset Machine Line:

Aborts all machines, puts them all into a pause state, and clears all internal machine line information. After pressing this button, all doors will need to be manually fed out of the machines as the application no longer has infor-mation about the doors.

Queued Jobs

The screen capture on page 2-19 , shows the stop notifications at the top in red and the exiting the line notifications at the bottom in green. The user can select once to dismiss notifications.

Stop notifications are shown when a door job is downloaded/barcode read and pause the ON-2015-E, exiting the line notifications are shown when the door job exits the Endeavor.

The long number in the notification message is the door job name/door id, it’s the same thing that will show in the Machine Activity Job Name column


2-20

Quick Start

Quick Start

Ensure factory air and power is present at the machine. For more information: See “How to Power Up the Endeavor” on page 2-23

1. Turn on the machine main air supply valve.

2. Turn on the Red Power lever the Electrical Panels.

3. Turn on the Green Control Transformer lever on the Operators Station.

4. Press the Green Start button to boot-up into Desktop environment.

After the computer is completed booting up, the Kval User Interface and Kval2015 program will start automatically. However, for instruction purposes, below are manual steps to start the programs

Double Click the Kval2015.exe desk-top icon.

Double Click the Kvalshell.exe desk-top icon.

After the KvalShell.exe is started, select the Home Machine Button and

the Auto Feed ON Button from the Main Control Section.

For more information: See “Home the Machine” on page 2-24 .

2-21


Quick Start

After the door has completed the Home sequence:

If the machine has a barcode scanner, the machine is ready to process a door. Go to Process a Door.

If running manually, select a file from the template menu

Select the Download button the template for processing.

OR

Ensure all machines in the line are Powered, Homed, and set to Auto.

Go to the Kval User Interface Main Menu and select the Feeder Menu

Load doors into Door Stack area

Enter number of doors to process.

To start the automatic processing cycle, select Stack # (1or 2) from the Stack

Select Menu.

Press the Run button to start the process

If completed for the day, power down the machine. For more information: See “How to Power Down the Machine” on page 2-24

1. Press the Red Stop button, located on the Operators Station.

2. Shut down the operating system, by selecting Shutdown from the Desktop.

3. After computer has fully shutdown, turn off the Green Control

Transformer lever on the Operators Station.

4. Turn off the Red Power lever the Electrical Panels.


2-22



This section describes how to power up and to power down the Endeavor.

Powering up the system includes:

• Applying power to the entire system

• Starting the Control CircuitPowering down the system includes:

• Shutting down the control power

• Removing power from the entire system

How to Power Up the Endeavor

1. Ensure factory air is applied to machine and main air supply is turned on.

2. Check that all E-Stop buttons are out and safety gate door s are closed.

Note: A pop-up is displayed on the user screen if an E-Stop is pressed. The pop-up will indicate which E-Stop has been activated

3. Make sure the electrical disconnect the electrical cabinet is turned to the ON posi-tion.

.

4. Switch the green CONTROL TRANSFORMER switch to the ON position. It should light up.

5. Push the green START MACHINE button to “boot up” the machine.

Note: Boot up may take 2 to 3 minutes.

6. All lights on the status light panel on the electrical box should be illuminated. See “Description of the Six Light Panel” on page 2-16

Note: If a status light does not turn on during the power up pro-cess, see “Troubleshooting with the Status Light Panel” on page 6-12 for assistance in identifying the issue.

2-23



Home the Machine

The Endeavor must go through a homing routine before any operations are performed. The hom-ing routine sets a zero reference from which the Endeavor measures its movement and cutting process.

If power is lost or the Endeavor is re-set, the homing routine must be performed again to reset the zero reference.

Press the Home button on the Main Control Screen

How to Power Down the Machine

1.

1

2

3

Push the Stop button, located on the Operator’s Station

2. Shut down the operating system, by selecting Shutdown from the Desktop.

Note: Make sure Windows is shutdown completely before turning off the machine. Hard drive or data may be damaged if not turned off in this order.

3. Switch the green CONTROL TRANSFORMER switch to the OFF position.

4. KVAL also recommends that you turn the disconnect switch on the electrical cabinet to OFF; this helps reduce possible damage resulting from power surges from electri-cal storms.

1. The machine will move to the home position at the in-feed end of the machine.

2. The machine will then move to about the middle of its travel.

The Endeavor is now ready for work.


2-24


Emergency Shutdown and Recovery

There are emergency shutdown (E-Stop) switches located at key points around the machine.

Note: Depending on options of the machine, the E-Stop buttons may be located at various locations.

The E-Stop switches are to be used when the machine is out of control or is about to damage personnel or equipment.

When an E-Stop switch is activated, power to the machine is killed.

The machine responds, in the same way, if you press the STOP button on the operator's station.

2-25


Sequence of Operation

Sequence of Operation

1. Door Feeds in from previous machine

2. Front sensors signal that door has entered

3. Pop back fence is activated

4. Door is pressed against the Door Stops located at the Out-Feed of the machine.

5. Door pushers move the door against the fence while the encoders measure the door.

6. The Clamps on the Lock side come down to the door.

7. The Lock side pusher lightly touches the door while encoder takes measurement for the width of the door.

8. All feelers (Length and Width) take measurements

9. The machine starts to process the door.


2-26



The Endeavor interface has two software programs to control the machine.

1. The user interface is also the start up screen for the machine. From this program, the following can be performed.

• Start the machine

• Manual Operation

• Perform Calibrations

• Create Pre-Drill tem-plates

• Provide feedback about machine status.

2. The KVAL 2015 software program defines and executes door files which contains the specifications for the cuts the machine makes to the doors. This program is the “workhorse” to process the daily product.

2-27


About the KvalShell User Interface


This section describes the KvalShell user interface. This interface allows the operator to use a touch screen to control the door cutting process, auto-run, manually run the door, store door pro-files, and use diagnostics to help troubleshoot the Endeavor.

Screen Selection Menu Map

This display uses a tabbed method of navigating the program. Below is a map of program loca-tions and references to the sections where they are described.

From this screen, Home the machine, change speed, control feeds, clamps and able to stop machine.

See “Main Control Screen” on page 2-30.

From this screen, create Predrill templates and store them.

See “About the Predrill Tab” on page 2-34.

From this screen, move the Hinge Heads and Lock Heads in fine movements.

See “About the Predrill Tab” on page 2-34.

From this screen, Calibrate the front section and back section of the machine.

See “About Calibration” on page 3-2.

From this screen, check the status of the assemblies on the machine. See what state the assemblies are in.

See “About the Status Screen” on page 2-37.

From this screen, the feedback codes from the machine.

See “About the Log Screen” on page 2-38.

Main Control Screen Predrill Screen Manual Servo Control

Calibration Screen Status Screen Log Screen

FIGURE2- 18. High Level Menu Map of Main


2-28


About Preview Job

The Preview Job Screen is a tabbed selection that provides a snapshot of the location and design of the hinge and lock side cuts. Use the controls on the page to zoom in and out, and scroll across door.

FIGURE2- 19.

About Machine Feed Back

At the top left-hand corner of all user screens is status feedback information. The informa-tion generated is as follows:’

1. General Machine Status

2. Hinge Status

3. Lock Status

Note: Use this information to isolate issues if having problems with the machine.

2-29



About the Calibration Tab

The Calibration Tab leads to multiple screens to calibrate the servos for Hinge Heads, Lock Head, Door Feed, Head Axes, Chisels, and Router and Predrill. The calibration screens are described in detail in “Calibration of the Endeavor” on page 3-1

Menu Selections

Main Control Screen

The Main Screen is also the startup screen for the KvalShell interface. From this screen, all the basic user interface controls are available to run a door.

FIGURE2- 20. Main Control Screen


2-30


About the Main Control Section

Home Machine

This button starts the home sequence on the machine, which scans to find a physical ref-erence point on the frame. When this point is found, the position is stored and then used to calculate the location of all moves during the machine pro-cess. The home sequence must be performed every time the machine is powered up or reset.

Start Sequence

Select this button to start the sequence of running a door.

Reset Machine

If a fault occurs that cannot be cleared, press the Reset Machine button. This button will reset the machine to the start position. Press the Home button after resetting the machine

Safe Mode Enabled/Disabled

Select Safe Mode to enable or disable. In the Enable mode, the safe mode is active. In safe mode the machine will go through normal sequences except the cutting motors will be inactive. Use this mode to check the machine operation without making a cut on the door. In the Disabled mode the machine is in normal operation.

Abort Job

Select to stop (abort) the process of the door that is currently running.

Clear Remaining Quantity

Select this button to finish an in-process door and clear the quantity of doors selected in the in-feed stack.

Stop Downloads

Select this button to stop downloads to the KVAL2012 program.

2-31



About the Width Adjust and Feed Control Section

Manual Feed Control

• Reverse: Press and hold the Reverse button to reverse the feed of the door to the in-feed of the machine. To stop the feed, release the button.

• Forward: Press and hold the Forward button to move the door feed to the out-feed of the machine. To stop the feed, release the button.

• Feed Speed: Press the Feed button to select slow or fast speed.

Width Adjust

• Move Open: Press and hold the Open button to open the width adjust carriage. To stop the carriage, release the button. The carriage will also stop if the positive travel limit eye is activated.

• Move Close: Press and hold the Close button to close the width adjust carriage. To stop the carriage, release the button. The carriage will also stop if the negative travel limit eye is activated.

Feed Mode

Auto Feed On/Off or Feed Through

Select Auto Feed to choose Auto Feed On or Off or select Feed-Through mode from a drop down menu.

• In the On mode, the feed system will bring in and clamp a door, wait for processing to complete, then feed the door to out the next machine. The manual buttons will be deactivated.

• In the Off mode, use the Manual Feed controls to control the feed of the door.

• In the Feed Through mode, the door will feed to the out feed

Note: On Start up the default is in the Off mode.


2-32


About Other Controls

Toggle Clamp

Press to toggle the door clamps up or down.

Enable Feeler Adjust

Press to toggle the Feelers. Use this to recheck the feeler measurement.

About Speed Control

Routine Speed Percent

Press to control the speed of the door through the machine. The speed can be changed at real time processing.

2-33



About the Predrill Tab

Different patterns for predrill routines can be created, edited and stored by using this screen. Select the Predrill Tab to display the following:

Saved Predrill Patterns: Lists the stored patterns that have been created

Pattern Predrill Locations: Lists the X and Y positions of the selected Predrill Pattern

New button: Select to create new templates

Edit Button: Select to edit existing predrill templates

Delete Button: Select to delete existing templates

List of Saved Predrill PatternsLocations of the

predrill holes.

Buttons


2-34


How to Adjust the Predrill Parameters

To create a new template:

1. Select the New button to create template.

2. Enter the password in the pop-up menu

3. In the New Predrill Pattern Parameters Menu, enter the following:

a.Enter Custom Name,

b. Pattern ID (if needed)

c. Drill Depth.

4. Click in the Predrill Location box and enter the X and Y locations. For a description of references and drill hole location, see “Predrill Template References” on page 2-36 .

5. Select the Add Hole button to add the hole location to the template. If desired select Remove Hole to remove from template

6. Select the OK button when completed.

To edit an existing template:

1. Select a template from the Saved Pre-drill Patterns list

2. Select the Edit Button

3. .Enter new parameters in the Pattern

Predrill menu.

4. Select OK to complete the process.

To delete an existing template:

1. Select a template from the Saved Predrill Patterns list

2. Select the Delete Button

3. Answer yes to “Are you Sure” pop-up

4. Select OK to complete the process.

2-35



FIGURE2- 21. Predrill hole locations

About Manual Servo Control Tab

Manually control the servos on the Hinge Heads and the servos on the Lock Head from this tab.These functions are commonly used in troubleshooting or verifying movement of the hinge or back section.

Predrill Template References

Set the screw patterns for the point to point predrills. The X and Y valves are referenced off the bottom of the hinge on the door to the center of the hinge

The number '0' entered in both 'X' and 'Y' are equal to no drill.

See the figure below. Imagine a graph over the Hinge. The 'X' and 'Y' values in the graph are entered in the Sample Template screen shot below.

• The starting point for the 'X' location is the middle of the hinge using the at the center of the hole as a reference.

• The starting point for the 'Y' location is the edge of the hinge using the at the cen-ter of the hole as a reference.

• Never enter a negative number in the 'Y' parameter. The pre-drill will try to drill off the door into the Delrin.

'X' Zero Point

'Y' Zero Point

Door

Positive DirectionNegative Direction

Positive Direction

12

3

...


2-36


About the Status Screen

From this screen, real time feedback during the operation of the machine can be viewed. The feedback includes times, dates, and machine status. Status includes a “True” flag if the assembly is in operation or a “False” flag if not in operation. Also status can include data and motor states (idle, operation). The data can be filtered to observe certain aspects of the operation of the machine. This tool is great for troubleshooting to locate faulty assemblies.

Under the Head to move, press and hold the button to move the desired direction. To stop, release button Observe the position of the heads in the menu box. The speed is set at the factory and is cautiously slow.

2-37



.

FIGURE2- 22. Status Screen

About the Log Screen

The Log screen displays all the tasks the Endeavor performs. This screen can help with trouble shooting by associating the error code to machine sections or functions. The top line will have the most current routine that is running. The codes are color coded:

Red = ErrorGreen = Report is a non-issue

Yellow = Warning

If the machine issue can not be resolved, call KVAL Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the KVAL representative. This will aid in troubleshooting and shorten down time.

Filter Data

Status is listed by Location

List of Parameter of Door in Process


2-38


FIGURE2- 23. Log Screen

2-39


KVAL 2015 User Interface Visual Tour


The figure below outlines the main features of the KVAL 2015 user interface.

.

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.

These buttons are used while defin-ing or modifying door files or cut templates.

Edit Off- Click to start “Edit On”. Change Door specificationsSave- Click to save changes made to profileMaint- Click “Maint” once to open the Home Machine button (Home appears in button below it.) Click “Maint” twice to open the Calibra-tion button. Program-(name)-?Abort- Click to stop cut in process.Restart-Click to restart cut after abortLoad Programs-Observe the process of down loaded program?

Override Count-Click this button to finish processing the current door, but clear all subsequent door files. Download-Click this button to download the selected door file. The cutting commences after the door is clamped into the machineExit- Double Click to exit out of KVAL2012 Program

Displays the specs for a selected door, or for a selected cut.

This selection contains the view port, which displays parameters of cut.control of Database and Network connections. Count of the cuts performed. Indication of Red or Green to show if ready to cut.Button to go to “on the fly” Calibration. Diagnostics of pro-gram and Machine ID

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 displayed in inches in decimal form.


2-40


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.

Structure, how the program thinks:

The class structure is in three levels called doors, templates and shapes. Doors are a collection of templates. Templates are a collection of shapes. Shapes are a group of geometric primitives.

• Doors are defined by length, width, thickness, core, hinge bevel and lock bevel.

• Templates are defined by a location on the door.

• Shapes available are hole and rectangle and special.

• Holes are defined by location, diameter, bottom depth and top depth.

• Rectangles are defined by location, width, length, corner radius top depth and bot-tom depth.

• Specials are user defined custom shapes programmed by KVAL. Feel free to contact us for more information.

Note: There is lead time involved in special creation.

2-41


Door Files: Creation and Editing


Creating and Saving a Permanent Door File

This section describes how to create a permanent door file. The door file contains the specifica-tions for the door and the cuts to be made. Each cut (rectangle, hole, or special) is derived from a template. To streamline your operation, you should create permanent door files for standard doors.

You can create a new permanent door file from scratch, or you can derive the new door file from an existing door file. Once a permanent door file is created, you can execute the file in two differ-ent ways:

• Find the door file in the Merge List, double-click door file name, and click the Down Load button to initiate the cutting process.

• Use a barcode and barcode scanner to select and execute the appropriate door file for the incoming door. Contact Kval for help with setting up the barcode operation.

To modify an existing door file, See “Modifying (Permanently) an Existing Door File” on page 2-45. To delete a door file, See “Deleting a Door File” on page 2-48.

Tip If you want the door file parameters to stay the same, even if the templates are later changed, put an asterisk at the end of the door file name when you create the file (e.g., EZDOOR*).


2-42


Creating a New Permanent Door File

1. Click the Door or Lock button until you see the “Merge List.”

2. Click the Edit Off button until is reads Edit On (flashes).

3. Type the name of new door in Merge List field. For example, to name the new door “EZDOOR” it would look like this:

4. Press the Enter key. This creates a new door file and opens the Door Item List.

5. Add a template to the door file:

6. Click the Add Item button to begin the process of adding a tem-plate to the door file. Notice that the list of doors is replaced by a list of all available templates.

7. In the template list, find the template you want to add and then double-click it.

In this example, we used the 011SL cut. Notice that the name of template now shows in the field at the top of the list, the name of the door appears as the first item in the Merge List, and the template specifications are displayed.

8. Click the Add Item button again. This assigns the template to the new door file, and places the template name and its basic specifi-cations in the Door Item List.

9. To add more templates, click the Edit Off button until is reads Edit

On (flashes), then repeat the add-template process in Step 5 above. As more templates are added to the door file, they are dis-played in the Door Item List. In this example we added the DB1[2]

2-43



Creating a Permanent Door File from an Existing Door File

Use the following procedure if you intend to derive a new door file from an existing door file

1. . Click the Door or Lock button until you see the “Merge List.”


3. Find the existing door in the list and double-click on it to view its parameters in the Door Item List.

4. Click on Door ID #, type the name of the new door file in the field below Door ID #, and press the Enter key. For example, if the name of the existing door is “321DOOR” and you wish to call the new door file “DOORY” it would look like:

5. Click the Save button, and then click the OK to Save Door Template? button. This cre-ates a new door file (a copy of an existing file, but with a new name).

6. Click the Door or Lock button until you see the “Merge List.”

7. Locate the new door in the list and double-click it to view its parameters in the Door Item List.

8. Add templates to the door file, as needed. If you do not need to add templates, skip to Step 9.

d.Click the Add Item button to begin the process of adding a template to the door file. Notice that the list of doors is replaced by a list of all available templates.

e.In the template list, find the template you want to add and then double-click it. Notice that the name of template now shows in the field at the top of the list, the name of the door appears as the first item in the Merge List, and the template specifications are displayed.

f.Click the Add Item button again. This assigns the template to the new door file, and places the template name and its basic specifications in the Door Item List.

g.To add more templates, click the Edit Off button until is reads Edit On (flashes), then repeat the add-template process in Steps 8.a. through 8.c. above. As more templates are added to the door file, they are displayed in the Door Item List

9. Remove templates from the door file, as needed. If you do not need to remove tem-plates, skip to Step 10.

h. In the Door Item List, select the template you wish to delete.

i.Press the Delete button and then click the About to Delete OK? to delete the tem-plate, or click the Delete Cancel button to cancel the delete action.

j.To remove more templates, repeat Steps 9.b. and 9.c. for each template.

10. When you are finished adding and removing templates to the door file, click the Edit On button until is reads Edit Off.

11. To save the new door file, click the Save button and then click the OK to Change Door

Template? button.


2-44

mailto:[email protected]


Modifying (Permanently) an Existing Door File

Use the following procedure to permanently modify an existing door file.

To Make a Permanent Modification to an Existing Door File

1. Click the Door or Lock button until you see the“Merge List.”

2. Locate the targeted door file in the List anddouble-click it. This displays the specifications for that doorfile.

Tip: If the list is long, instead of scrolling to search for the door file, you can start typ-ing the name of the door file in the Merge List field above. The list automatically scrolls to the closest matching text string.


4. Add templates to the door file, as needed. If you do not need to add templates, skipto Step 5.

a.Click the Add Item button to begin the process of adding a template to the doorfile. Notice that the list of doors is replaced by a list of all available templates.

b.In the template list, find the template you want to add and then double-click it.Notice that the name of template now shows in the field at the top of the list, thename of the door appears as the first item in the merge list, and the templatespecifications are displayed.

c.Click the Add Item button again. This assigns the template to the new door file,and places the template name and its basic specifications in the Door Item List.

d.To add more templates, click the Edit Off button until is reads Edit On (flashes),then repeat the add-template process in Steps a through c above. As more tem-plates are added to the door file, they are displayed in the Door Item List.

5. Remove templates from the door file, as needed. If you do not need to remove tem-plates, skip to Step 6.

a.Click the Edit Off button until is reads Edit On (flashes).

b.In the Door Item List, select the template you wish to delete.

c.Press the Delete button and then click the About to Delete OK? to delete the tem-plate, or click the Delete Cancel button to cancel the delete action.

d.To remove more templates, repeat Steps b and c for each template.

6. (Optional) Normally, the templates you assign to a door file are global. However,you can make the templates tenant to the door file (unaffected by changes outside thedoor file). To do this, use the following procedure:

2-45



a.Click on Door ID and type in the name of the door followed by an “*” and press the Enter key. For example: if a door was called 1234 rename it to 1234*.

b.Edit the template parameters as needed.

7. When you are finished adding and removing templates to the door file, click the Edit

On button until is reads Edit Off.

8. To save the new door file, click the Save button and then click the OK to Change Door

Template? button.


2-46


Merging Doors

Creating Door Templates From Merged Doors

From main menu click on door or lock button and watch text in upper right (Blue Box).

1. Click to Door Menu

2. Click on Edit button

3. Click in upper right Text Box (Blue Box) and type in desired door name.

4. Click Next Num-Merge button until Merge appears.

5. Single Click on the door to be copied into the new name.

6. Or (CTRL click on multiple doors on list)

7. Hit OK to merge,

8. This new door can be saved or downloaded without saving.

2-47



Deleting a Door File

If you no longer need a door file, you can delete it permanently from your door file list

CAUTION: Once a Door File or Template is deleted, there is no way of getting it back. It is up to the user to backup machine files so the system can be restored in the event of

a computer failure or accidental deletion of critical data.

.

To Delete a Door File

1. Click the Door or Lock button until you see the“Merge List.”

2. Click the Edit Off button until is reads Edit On

(flashes).

3.

or

In the list, click on the door file you wish to delete.To select multiple doors, use the shift-click method or the Ctrl-click method.

4. Press the Delete button and then click the About to Delete OK? to delete the template, orclick the Delete Cancel button to cancel the delete action.

5. Repeat Steps 3 & 4 for each door file you wish to delete.

6. When finished, click the Edit On button until the button name changes to Edit Off.


2-48


2-49



CHAPTER 3 Calibration of Endeavor

This chapter describes the steps to calibrate the Endeavor System.



About CalibrationGeneral information about calibration. Steps to look for before calibration.

page 3-2

About the Calibration TabSummary of calibration choices. Access to the Cali-bration Menus. How to enter Calibration Data. How to create Restore Points. About the direction of the servo motors.

page 3-3

About the Door Feed Setup About the Width and Door Feelers Adjustments. This is the first adjustment to view or complete.

page 3-6

About the Hinge Head Menu

All about the Hinge Head Calibrations. page 3-8

About the Lock Head Menu

All about the Lock Head Calibrations. page 3-13

About the Calibration Reference Cut

How to create a Reference Cut. Dimensions explained. Steps to use calibration cuts for Hinge Heads and Lock Heads

page 3-19

3-1


About Calibration

About Calibration

Calibration is all about the confidence in the end results of your manufacturing process. Calibra-tion assures you that your cut parameters are accurate and within the specified limits.

If slight discrepancies in the machining of a door are observed, the built in KVAL calibration can adjust the tooling to fix the issue.

In troubleshooting, calibration can be an essential step in solving the issue.

About the Calibration Menus and the Calibration Reference Cut

This chapter describes the Calibration Menus and to how to perform a Calibration Reference Cut.

In the Calibration Menus, offsets are entered to calibrate assemblies in the machine. See “About the Calibration Tab” on page 3-3.

The Calibration Reference Cut delivers a calibration cut for the Hinge Heads and for the Lock Head. Use the Calibration Menus to adjust the tool sets from information taken from the calibra-tion cuts.See “Start the Calibration Reference Cut” on page 3-20.

1. Hinge Cut: Performs a cut to verify the Predrill, Hinge Router, and the Counter Rotate Router.

2. Lock Cut: Performs a cut to verify the Predrill, Counter Rotate Router, Plunge Router, Plate Router, and the Deep Mortise Router.

Before you Calibrate

Before you start calibration, check for the following common issues.

1. Is the loaded setup correct for the current cut?

2. Check tools for wear.

3. Is the correct Calibration loaded?

4. Are the stops set up correctly?

5. When did the problem first start? during a run, at start up.

6. When was the last calibration?

7. Is the Door True?

8. Use Router Bit Depth Gauge (PN: 432C) to check depth.

9. Check for sawdust build-up, which may affect depth.

Note: KVAL recommends that a test door is run first and checked for specifications before a full run is started.


3-2



The Calibration Tab contains access to screens to adjust servo motors in the machine.These soft-ware routines are designed to fine tune the servos for optimum accuracy. The maximum adjust-ment is 0.50 inches for all calibrations.

Note: If more than 0.50 inches of adjustment is needed, there is a high probability that another issue may be causing a problem. Perform a visual check of the assembly to be calibrated and check the Status Screens and Log Screens for error reporting. Finding errors from these screens will help localize problem areas.

Note: If the machine issues can not be resolved, call KVAL Inc. (1-800-553-5825). Have any error code that is displayed, ready to give the KVAL representative. This will aid in troubleshooting and shorten down time. See “Getting Help from KVAL” on page 1-14.

Access to the Calibration Routines

Under the calibration tab, there are routines to calibrate the machine. Fine adjustments can be made to the location of the tools by adjusting the servos. Buttons to unlock access to calibration, save a calibration, and restore calibration are located here. Top level tabs that access the calibra-tions are listed below.

• Hinge Heads 1 and 2

• Lock Head

• Door Feed Status

Calibration Tab:

Select to enter the calibration screen

Calibration Tabs:

Top Level, Select to access calibra-tion routines

Calibration Buttons:

Unlock a Calibration

Save a Calibration

Restore a Calibration

FIGURE3- 24. Calibration Header

3-3



Unlock the Calibration (Option)

Access to the calibration is password protected. (Optional)

1. Select the Unlock button

2. At the Password pop-up, enter the password to continue.

3. The calibration message will change from a red ''Calibration is Locked '' to a green Calibration is Unlocked”.

Enter a Positive or Negative Number?

Determine when to enter a positive of negative number by using your Right Hand. Use the cut on the door as a reference. Hold out the right hand with the first finger pointed at the door, second finger and thumb at right angle to each other. The first finger represents the positive direction of the ‘Z” axis, the thumb represents the positive direction of the ‘Y” axis, then second finger rep-resents the positive the direction of the ‘X’ axis.

Y +

Y-

X Axis Positive movement

Z Axis Positive movement

Y Axis Positive movement

Z -

X -

Y +Z +

X +

Either Front Section or Back Section Cuts

FIGURE3- 25. Right Hand Rule


3-4


How to Enter Calibration Data

Adjustment menus are located in the setup screens. In these menus, you can add negative or posi-tive adjustments to move a servo to desired positions to compensate (calibrate) for any deviation’s from the expected cut. The calibration can then be stored.

Below are general instructions to perform a calibration.

1. Check for deviations in the expected machining and actual machining. Measure the offset from the expected result. Use this number to enter into the offset box under the inaccurate parameter.

Note: Maximum offset is 0.50 inches. If more than 0.50 inches of adjustment is needed, there is a high probability that another issue may be causing a problem. If issues can not be resolved, contact the KVAL Service Center KVAL Inc. (1-800-553-5825). See “Getting Help from KVAL” on page 1-14.

2. Enter the offset positive or negative number in the white box below the Offset title to adjust the servos in the X, Y, and Z directions.

3. The Base display box keeps a running total of data entered to help keep track of the changes.

4. The Combine button merges the offset number to the base to adjust the servo.

5. Run a test door again to verify the offset correction was successful.

6. Keep running a test door and adjusting the offset until satisfied with the result

7. After satisfied, click the Save button to store the calibration.

About Restore PointsRestore Points can be created to store a calibration point for recall.

To create a Restore Point:

1. Select the Restore Points button

2. Select the Save Current button from the pop-up window save current calibration

3. Name and enter to save

To Load or Delete a Restore Point:

1. Select the restore point from the menu

2. Select the Load button to use the calibration. Select the Load button to load

3. Select the Delete button to delete the point.

3-5


About the Door Feed Setup


This menu calibrates the Door Width Clamping assembly and the Door Width Feelers that mea-sure the door width and door length.

Important: Setting the Door Feelers is first calibration that should be checked or performed. The calibration adjusts the encoders located in on Hinge Heads (width) and on the In-Feed and the Out-Feed. These calibrations are a starting reference for all calibrations. The Door Feed Setup has one menu screen.

Troubleshooting Tip: If all cuts are 'off' reference on the front section and the back section, look to this menu to adjust the settings.

Door Feed Setup

Door Width FeelersWidth Adjust Door Length Feelers Door Thickness Feelers

About the Width and Door Feelers Adjustments

FIGURE3- 26. Door Feed Setup


3-6


Width Adjust Adjustment

The Width Adjust calibrates the width clamping assem-bly on the machine.

Process: If width clamping is not clamping correctly, either too tight or too lose, enter the offsets below to achieve a correct fit.

Enter a positive offset to move the width adjust clamps closer.

Enter a negative offset to move the width adjust clamps further apart.

Door Feelers Adjustments

Important: Setting the Door Feelers is first calibration that should be checked or performed. This calibration adjusts the encoders located in on Hinge Heads These calibrations are a starting reference for all calibra-tions.

Process:

1. Measure a know good door. The door should be true and possible. Capture the width and length measurements. (These measurements are used to compare to the width and the length feed backs from the encoders.)

2. Ensure the Safe Mode is Enabled (no cutting). Select the Main Con-

trol Tab and under the Main Control Section select the Safe Mode but-ton.

3. Turn on auto feed. Select the Main Control Tab and under the Width

Adjust and Feed Control Section select the Auto Feed On button.

4. After the door has been fed in, Check the measurements fed back from the encoders. Select the Log Tab and check the latest feedback from the Hinge Heads, Infeed, and Out-Feed encoders.

5. Get averages of the feedback.Write down the measurements. Reverse the door and re-feed it in at least 5 times. compute the averages of the fed-back measurement.

6. Enter the offsets from the averages and the measured door in the boxes under the Door Width Feelers and Door Length Feelers Menus.

7. Enter a negative offset to move the width adjust clamps closer.

8. Enter a positive offset to move the width adjust clamps further apart.

3-7




Below is a menu map of the selections available under the Hinge Head Calibration tab. These selections are described in this section.

Head Axes Chisels Router + Pre-Drill

CW Router

CW Bit Diameter

CW Router X,Y, and Z

Hinge Head 1-2

CCW Router

CCW Bit Diameter

CCW Router X,Y, and Z

Pre-Drill

Pre-drill X,Y, and Z

Push Over

Axis X,Y and Z

Tools (Bevel 3)

Axis Y and Z

Tools (No Bevel)

Axis X,Y,and Z

Upper Left Chisel

Axis X,Y and Z

Upper Right Chisel

Axis X,Y and Z

Lower Left Chisel

Axis X,Y and Z

Lower Right Chisel

Axis X,Y and Z

FIGURE3- 27. Hinge Head Menu Map

About Head Axes Calibration

Click the Head Axis Tab to adjust the Tools and the Door Push Over. If the Hinge pocket and Pre-drills are out of the expected results, use the Tools Section. If the Side Ram is not pressing against the door or not aligned correctly, use the Side Ram section.

Note: Maximum offset is 0.50 inches. Hinge Heads 1 and 2 have the same calibration parameters.


3-8


.

Tools:

Adjusts the tool set (Chisels, Router, and Predrills) within the Hinge Head.

Push Over:

Adjusts the door pusher. The door pusher pushes the door to the back fence and uses an encoder to measure the door width

FIGURE3- 28. Head Axes Calibration menu (Hinge Head)

Head Axis Adjustments

A Positive ‘Y’ Offset will move the complete Hinge Cut up

A Positive ‘X’ Offset will move the complete Hinge Cut as shown

Y: + Offset

X: - Offset

A Positive’ Offset will move the Pushover into the door

Z: + Offset

Y: + OffsetA Positive ‘Z’ Offset increases depth

A Positive ‘X’ Offset will move the Push-over as shownY: -

X: +Z: -

Y: -

3-9



About Chisels Calibration

Click the Chisels Tab to adjust the Left and Right chisels on the Hinge. If the corners of a square cut on a hinge are offset.

Note: Maximum offset is 0.50 inches. Hinge Heads 1 and 2 have the same calibration parameters.

FIGURE3- 29. Chisels Calibration Menu (Hinge Head)

A Positive ‘X’ Offset will move the Chisel cut as shown

A Negative ‘X’ Offset will move the Chisel cut as shown

A Positive ‘Z’ Offset increases depth

A Negative ‘Z’ Offset decreases depth

Lower Left Chisel

Lower Right Chisel

X: - Offset

Y: + Offset

X: + Offset

Upper Right Chisel

Upper Left Chisel

Y: - Offset

Chisel Adjustment (Lock Head)


3-10


About Hinge Router and Predrill Calibrations

Select the Router + Predrill calibration if the predrill holes are offset or the hinge pocket is mis-shapen or offset. Hinge Heads 1 through 4 have the same calibration parameters.

Note: Maximum offset is 0.50 inches.

FIGURE3- 30. Routers -Predrill Calibration Menu (Hinge Head)

A Positive ‘X’ Offset will move the Router cuts as shown

A Negative ‘X’ Offset will move the Router cuts as shown

X: - Offset

Y: - Offset

X: + Offset A Positive ‘Y’ Offset will move the Router cuts ‘up’.

A Negative ‘Y’ Offset will move the Router cuts ‘down’.



The Router Diameter can compensate for a bit wearing out. Positive increases diameter. Negative decrease diameter

Hinge and Counter Rotate Router Adjustments

Y: +Offset

3-11



Y: + Offset

X: - Offset

Y: - Offset

X:+ Offset

A Positive ‘Y’ Offset will move the Predrill cuts in the up direction

A Negative ‘Y’ Offset will move the Predrill Cuts in the down direction.

A Positive ‘X’ Offset will move the Predrill cuts as shown

A Negative ‘X’ Offset will move the Predrill cuts as shown



Predrill Adjustments


3-12

About the Lock Head Calibration Menu


Below is a menu map of the selections available under the Back Section Calibration tab. These selections are described in this section.

Head Axes Chisels Routers

Upper Left Chisel

Axis X,Y and Z

CW Router

CW Bit Diameter

CW Router X,Y, and Z

Lock Head

CCW Router

CCW Bit Diameter

CCW Router X,Y, and Z

Upper Right Chisel

Axis X,Y and Z

Side Ram

Axis X,Y and Z

Tools (Bevel 3)

Axis Y and Z

Tools (No Bevel)

Axis X, X,Y,and Z

Lower Left Chisel

Axis X,Y and Z

Lower Right Chisel

Axis X,Y and Z

Short Bit Diameter

Short Bit Diameter

Short Router X,Y, and

Deep Mortise & Predrill

Deep Mort. Router

Deep Mort Bit Diameter

Deep Mort Router X,Y, and Z

Predrill

Predrill X,Y, and Z

FIGURE3- 31. Menu Map Lock Head

About Head Axes Calibrations (Lock Head)

Select the Head Axes calibration if all machine cuts in the lock section (vary with the same offset) from the expected results.


3-13



FIGURE3- 32. Head Axes Calibration Menu (Lock Head)

About Chisel Calibrations (Lock Head)

Select the Chisels calibration if the corners of a square cut on the lock plate are rounded or offset.


Y: + Offset

X: -Offset

Y: - Offset

X: + Offset

A Positive ‘Y’ Offset will move the Lock Cut in the up direction

A Negative ‘Y’ Offset will move the Lock Cut in the down direction

A Positive ‘X’ Offset will move the Lock Cut as shown

A Negative ‘X’ Offset will move the Lock Cut as shown



Head Axis Adjustments


3-14


FIGURE3- 33. Chisels Calibration Menu (Lock Head)

A Positive ‘Y’ Offset will move the Chisel in the up direction

A Negative ‘Y’ Offset will move the Chisel in the down direction

A Positive ‘X’ Offset will move the Chisel cut as shown

A Negative ‘X’ Offset will move the Chisel cut as shown



Lower Left Chisel

Lower Right Chisel

X: - Offset

Y: + Offset

X: + Offset

Upper Right Chisel

Upper Left Chisel

Y: - Offset

Chisel Adjustment (Lock Head)

3-15



About Router and Bolt Drill Calibrations (Lock Head)

Select the Router + Bolt Drill calibration if the lock hole is offset or the lock plate is misshapen or offset.


FIGURE3- 34. Routers Calibration Menu (Lock Head)

A Positive ‘X’ Offset will move the Router cuts as shown

A Negative ‘X’ Offset will move the Router cuts as shown

Y: + Offset

X: - Offset

Y: - Offset

X: + Offset A Positive ‘Y’ Offset will move the Router cuts in the up direction

A Negative ‘Y’ Offset will move the Router cuts in the down direction



The Router Diameter can compensate for a bit wearing out. Positive increases diameter. Negative decrease diameter

Router Adjustments (Lock Head)


3-16


About the Deep Mortise and Predrill (Lock Head)

Select the Deep Mortise calibration if all machine cuts in the lock section (vary with the same offset) from the expected results.


FIGURE3- 35. Deep Mortise and Predrill Calibration (Lock Head)

Y: + Offset

X: - Offset

Y: - Offset

X:+ OffsetA Positive ‘Y’ Offset will move the Plunge Router cut in the up direction

A Negative ‘Y’ Offset will move the Plunge Router cut in the down direction

A Positive ‘X’ Offset will move the Plunge Router cut as shown

A Negative ‘X’ Offset will move the Plunge Route cut as shown



Plunge Router Adjustments (Lock Head)

3-17



Predrill Adjustments (Lock Head)

The adjustment steps for the Lock Head Predrill are the same as the Carriage Head Pre-drill. See “Predrill Adjustments” on page 3-12.

The Predrill on the Lock Side is an Option. your machine may not have one.

Y: + Offset

X: - Offset

Y: - Offset

X: + Offset

A Positive ‘Y’ Offset will move the Deep Mortise cut up direction

A Negative ‘Y’ Offset will move the Deep Mortise cut in the down direction

A Positive ‘X’ Offset will move the Deep Mortise cut as shown

A Negative ‘X’ Offset will move the Deep Mortise cut as shown



Deep Mortise Adjustments (Lock Head)


3-18



After checking for common errors, start the calibration cut process.

The calibration routine routes a horizontal slot and drills a center hole at precise specifications. The Lock Head and Hinge Head have separate calibration cuts for each head. Using these specifi-cations as a reference, you can inspect the pattern and the specifications of the slot for inaccura-cies. If inaccuracies are found, make adjustments though the Calibration Menus.

Hinge Head Reference Cuts

The Hinge Head Calibration cut is an oval. The Predrill, Counter-Rotate Router, and the Hinge Router are checked. The sequence of machining is described below.

The Sequence is:

1. Counter Rotate Router

2. Predrill

3. Hinge Router

CRR

Lock Head Reference Cuts

The Lock Head Calibration cut is an oval. The Plate Router, Counter-Rotate Router, Plunge Router, Predrill, and Deep Mortise are checked. The sequence of machining is described below.

The Sequence is:

1. Plate Router


3. Plunge Router

4. Predrill

5. Deep Mortise

3-19



Start the Calibration Reference Cut

Step 1. Select a door

a.Try to use a 1 ¾” with enough clear space to run the calibration routine multi-ple times, if necessary.

b.Each calibration cut will require approximately 2.0” of space on the hinge side of the door, and, 6.0” of space on the lock side.

c.It is recommended to verify the door length and width by performing the Door

Feeler adjustments.See “Door Feelers Adjustments” on page 3-7.

Step 2. Build calibration door program in KVAL2012

a.Create a door file that contains 3 cylindrical cuts.

b.Make sure all cylindrical are set for 0.005 depth.

c.Make sure the door specifications match the door being used.

d. Put two of the cylindrical cuts on the Hinge Edge and one on the Lock Edge.

Put 2 cuts on the Hinge Edge

Put 1 cut on the Lock Edge

e.Space the 2 Cylindrical cuts on the hinge edge a minimum of 32.0'' apart


3-20


Step 3. Download the Calibration Program and Setup Safe Mode

Step 4. Feed the Door into the Machine and Check Door Width Clamping

Step 5. Check Router Locations with Safe Mode On

a.Watch the heads individually as they run and make sure the router being used in each step lines up with the side of the door.

a.On the KAL2015 program, select the Download button to download program file.SE.

b.Select the Main Control

Tab and Verify the Safe

Mode is Enabled.

c.Set the Routine Speed to 25%.

a.Select the Auto Feed Button to turn it on.

b.Verify that the door is clamping correctly. If the door clamp is too wide or too narrow,see “Width Adjust Adjust-ment” on page 3-7 for calibration directions.

The Sequence is:


2. Predrill

3. Hinge Router

Hinge Heads Lock Head

The Sequence is:

1. Plate Router


3. Plunge Router

4. Predrill

5. Deep Mortise

3-21



b.If the Routers are not aligned, go to the corresponding calibration menu and make adjustments. See “About the Calibration Tab” on page 3-3 , for calibra-tion information.

c.If needed, make adjustments and continue to next step.

Step 4. Run Calibration Program with Safe Mode Disabled.

Step 5. Measure the Calibration Cuts.

a.Toggle the Safe Mode Button to Disable to activate cut-ting.

b. Download the door file again from the KVAL2015 inter-face.

c.To feed the door in and make the calibration cuts, turn the Auto Feed off then back on.

d.When the machine has finished the cuts, turn off the Auto

Feed and feed the door out.


3-22


a.Measure and compare the cuts to the calibration specifications below.Note the differences to prepare to go to the Calibration Menus and enter offsets.

Diameter of Deep Mortise Bit

Hinge Heads

Lock Head

Counter RouterCounter Router

Hinge Router

Step 6. Enter Offsets from Measurements into Calibration Menu

a.Any differences noted in the calibration can be compensated for by entering the measured changes from the reference into the calibration menu. For infor-mation on entering data, see “How to Enter Calibration Data” on page 3-5 .

b.Go to the appropriate calibration menu as listed below.

Step 7. Verify Calibration after Offsets are Entered Calibration Menu

a.Keep Running Calibration Cut until all cuts are in specification.

Step 8. Create a Restore Point

• Counter Rotate Router: See “Hinge and Counter Rotate Router Adjustments” on page 3-11.

• Predrill: See “Predrill Adjustments” on page 3-12.

• Hinge Router:See “Hinge and Counter Rotate Router Adjustments” on page 3-11.

Hinge Heads

Lock Head

• Plate Router: See “Router Adjustments (Lock Head)” on page 3-16.

• Counter Rotate Router:See “Router Adjustments (Lock Head)” on page 3-16.

• Plunge Router:See “Plunge Router Adjustments (Lock Head)” on page 3-17.

• Predrill:See “Predrill Adjustments (Lock Head)” on page 3-18.

• Deep Mortise:See “Deep Mortise Adjustments (Lock Head)” on page 3-18.

3-23



a.After all calibrations are in specification, create a restore point to save the changes. See “About Restore Points” on page 3-5.

b.Calibration is complete.


3-24

CHAPTER 4 System IT Administration

This chapter describes the KVAL Endeavor controller. The controller is an on board computer that supplies the user interface and controls the operation of the machine. With the controller, KVAL can remotely help troubleshoot your machine.



System IT Administration This chapter describes the basic parts of the operation of the PLC in the machine. Such as

• About the PLC

• Connections on the PLC

• Backing up the Computer

• About Remote Connection to KVAL Service

page 4-2

4-1


System IT Administration


For optimum support, the Endeavor requires internet access. With internet access, KVAL Service Support will be able to access your machine through your company’s Intranet and help solve any issues that may occur. Connection to the Intranet is achieved by interfacing with the Endeavor controller. The location of the Intranet connection is identified in the figure below (RJ45 to Intranet.)

About the Endeavor Computer

The Endeavor uses a Beckhoff® CPU module as a PLC (Programmable Logic Controller.) In addition to the CPU and the chipset, the module also contains internal main memory. The com-

puter has a removable Compact Flash card from which it boots.The controller uses a Windows 7®

operating system with TwinCAT 2® automation software to create the PLC and Motion Control method.

Interface modules include:

• A smart power supply to connect to EtherCat® terminals. This supply contains a LCD to display system and user messages.

• A DVI/USB module to connect to the user interface.

• An Ethernet module to connect to the servo amplifiers.

Connections on the PLC

The CPU module is located in the upper left corner of the Electrical Panel. See “About the Electri-cal Panels” on page 2-15. The figure below shows an example of a common PLC. Refer to the electrical drawing for detailed information.

Smart Power Supply and EtherCat

DVI/USB Module to User Interface

CPU Module

RJ45 to Intranet

Compact Flash Card

Interface to Servos

may contain more than 1 connection

Battery Interface to Frame


4-2


FIGURE4- 36. Connections on the Controller

Backing up the Computer

Backups keep your data archived in case of a rare system crash. Click the Back-Up Icon on the

Desktop to back up your data. The data is stored in a backup folder in your Windows® directory. It is recommended to set up a back-up schedule to save your data on a regular occurrence.

The KVAL service team would be happy to help. If any questions occur, contact our service team at (800) 553-5825 or at www.kvalinc.com.

About Remote Connection to KVAL Service

Remote access is a powerful tool to help fix issues that occur with the Endeavor machine. With the remote access, our KVAL service technician is able to observe your user screen in real time, read and adjust programming code. See “How to Download the Service Application” on page 1-16. for download information of service application.

4-3




4-4

CHAPTER 5 Maintenance of the Endeavor

This chapter describes preventative maintenance steps for KVAL Endeavor. The content is geared to guide technicians to keep a regular maintenance schedule for your KVAL machine. Keeping your KVAL machine maintained is an important piece for successful operation of your door pro-duction process.



Maintenance Schedule This section describes the assemblies to schedule for maintenance.

• Daily

• Weekly

• Six Month Checkups

page 5-2

Lubrication Requirements

This section describes the lubrication requirements for the machine, including types of lube to use. This section includes:

• Linear Bearings, Flange Bearing, and Pillow Blocks

• Gear Motor Lubrication Requirements

• Ball Screws

• Description of Air Input System

• Adjusting the Air Line Lubricator

• Priming the Air Line Lubricator

page 5-4

Replacing Bits This section describes the methods to replace bits on the machine.

page 5-7

Replacing the X-Axis Self Lubricator

This section describes the methods to replace X-Axis Self Lubricator

page 5-12


Maintenance Schedule


KVAL recommends the following maintenance schedule to ensure that the machine operates properly. Refer to this section for steps to perform maintenance.

Daily, Monthly, Six Month

Daily Preventive Maintenance

Op Operation Description

Clean Blow off dust from the entire machine.Wipe down the outside of the machine with a clean dry cloth.

Check Check tooling for wear.

Clean Wipe off the photo eyes with a clean dry cloth, and check to ensure that all fastening nuts are snug.

Check Check the air pressure to make sure it is set at 80 psi to100 psi.

Clean Empty any Dust Collection Units.

Check Check for obstructed flow when excessive sawdust appears.

Check Check the air filter water trap. Empty if full.

Maintenance

Weekly Preventive Maintenance


Check Check the machine for smooth motion through a complete door cycle

Clean Clean linear bearings and the chrome shaft with a clean dry cloth, then lubricate.

Check Check all air lines & electrical wiring for kinks or rubbing.

LUBE Refill lubricator with an ISO 32 standard hydraulic oil (KVAL part# SYSLUBG)

Six Month Preventive Maintenance


Clean Wash filter and lubricator bowls with soapy water.

LUBE Grease all bearings and tighten all bolts. Access to some grease fittings is difficult and will require a special needle point grease tip (supplied with your system).

Clean Clean and lubricate all slides and cylinder rods with dry silicone spray.

Tighten Tighten all bolts.

Back-up Backup computer software.

LUBE Lubricate linear bearings and chrome shafts with silicone.



Lubrication Schedule

KVAL recommends the following lubrication schedule to ensure that the machine operates prop-erly.

TABLE 5-2. Recommended Lubrication Schedule

Type of Assembly Recommended Schedule Recommended Lubrication Type

Linear Bearing

Every 250 Hours of Machine Operation Dura-Lith Grease (KVAL P/N Lube EP-2)Pillow Block Bearing

Flange Block Bearing

Ball Screw Every 80 Hours of Machine Operation

Air Line Lubricator One drop of oil every 2 or 3 cycles

Check the lines every week to two weeks

Either lubricant listed below is approved to use.

• KVAL P/N SYSLUBG

• Chevron AW Hydraulic Oil 32

• G-C lubricants light AW R&O

• Mobile DTE 24

• Shell Tellus32

• Gulf Harmony 32

Gear Box 2000 Hours of Machine Operation or six months of operation

• AGMA #8 gear lube

• MOBILUBE HD 80 W-90

• or equivalent




This section describes the parts of the machine that require periodic lubrication, and specifies the lubricants. In addition, it explains how to maintain the lubrication systems on the machine.

Linear Bearings, Flange Bearing, and Pillow Blocks

If the bearing is equipped with a grease fitting (Zerk Fitting), it should receive 1 Gram (one pump from grease gun) of Dura-Lith Grease (KVAL P/N Lube EP-2) every 250 hours of operation.

Note: Bearings without grease fittings have been pre-lubricated at the factory and do not require further lubrication.

FIGURE 5-37. Zerk Fittings

Zerk Fittings

Zerk Fitting Location Depends on Position of

Slide



Gear Motor Lubrication Requirements

Oil change is recommended after 2000 operation hours of operation. Use AGMA #8 gear lube or MOBILUBE HD 80 W-90 or equivalent.

Ball Screws

All ball screws should be lubricated Dura-Lith Grease (KVAL P/N Lube EP-2) for every 80 hours of operation. At each lubrication grease should be pumped into the fitting until clean grease comes out around the ball screw.

Ball screw lubrication points.

Ball NutBall Screw

EndBearing

EndBearing

FIGURE 5-38. Example of a Typical Ball Screw

Important: Make sure to clean excess grease to avoid contact with feed belts, clamping areas, or the door.

Description of Air Input System

The air input system takes in shop air and supplies clean dry air (CDA) and lubricated air to the machine. The clean dry air is diverted to blow off nozzles. The lubricator, located after the CDA filters, delivers the lubricated air to valve banks and air cylinders.

Shop Air

Input

Air On- Off Knob

Muffler

Filter (purge)

Pressure Gauge with adjust Clean Dry Air (CDA) to Air Blow Off

Lubricator

Lubricated Air Output

FIGURE 5-39. Typical Air Line Filter and Lubrication System



Adjusting the Air Line Lubricator

Using the knob on the top of the lubricator, adjust until one drop per every other cycle is used (as observed through sight glass.)

Priming the Air Line Lubricator

New and used machinery run out of oil from time to time. It is a good practice to check your machine lubricator to insure that it is putting the proper dose of oil in the air lines. Usually 1 drop of oil every other cycle is a good rule of thumb. The approved list of oil for lubricators is as fol-lows:

• KVAL P/N SYSLUBG

• Chevron AW Hydraulic Oil 32

• G-C lubricants light AW R&O

• Mobile DTE 24

• Shell Tellus32

• Gulf Harmony 32 To prime the lubricator, find an air line on the carriage section of the machine that is energized, and disconnect it, allowing the air stream to bleed air pressure away from any persons. Direct the air stream at the machine so you can see when there is an oily film blowing out of the air hose. Repeat this same procedure for the back section and other trouble areas.

It is recommended to check the lines every week to two weeks.

(Sight Glass). When the oiler has run dry, open the knob all the way until flow begins. Once you have a steady flow, tighten knob back down until you have one drop per every other cycle.

Drop will form at end of cane shaped tube visible inside glass.

Top of Lubricator


About Replacing Bits


The Endeavor is a powerful electro-mechanical motion control system. If servicing the Endeavor fol-low the safety guidelines described in. Failure to do so can result in damage to equipment and/or serious injury to personnel.

Caution

Location of Tools in the Carriages

This section describes the steps to change the pre-drill bits, router bits, deep mortise and chisels. The next Figures show the locations of the tools on the Hinge Carriages.and the Lock Carriage.

Tool Location Hinge Carriage

.

Pre-Drill: Drills pilot holes for insertion of screws on the door

Hinge Router: Routs the hinge pocket

Chisels: four chisels the corner edges of the hinge pocket to cre-ate a square hinge

Counter Rotate Hinge Router: Routs the hinge pocket providing a clean cut.

FIGURE 5- 40. Hinge Carriages Tools



Tool Location Lock Hinge

FIGURE 5- 41. Lock Carriage Tools

Tool Collet Wrench and Shaft Wrench List

Tools are provided with the machine.

Hinge Carriage Wrench List

TABLE 5- 3. Hinge Carriage Wrenches

Assembly Type KVAL Collet Wrench PN KVAL Shaft Wrench PN

Pre-Drill Collet Wrench, ER20 Series, 1/2" Collet, 1 and 2 HP Perske , P/N: PERER20W

Shaft Wrench, 1 and 2 HP Perske Motor P/N: WRENCH22MM

Hinge Router Collet Wrench, ER25-M Finger, For Colombo 3 HP Hi-Frequency Motor COL

P/N: ER25-CW

Shaft Wrench, 24MM. P/N: WRENCH24MCounter Rotate Router

Pre-Drill (Option A): Drills pilot holes for insertion of screws on the door or

OPT: 8 ''Deep Drill

Plunge Router: Routs the lock hole in the door

Counter Rotate Router: Routs the pocket providing a clean cut.

Face Plate Router: Routs the Face plate pocket

Deep Mortise Router: Routs a deep pocket.

Chisels: Four chisels corner edges of the lock pocket to create a square pocket (Not shown in this illustration)



Lock Carriage Wrench List

TABLE 5- 4. Lock Carriage Wrenches

Assembly Type KVAL Collet Wrench PN KVAL Shaft Wrench PN

Pre-Drill Collet Wrench, ER20 Series, 1/2" Collet, 1 and 2 HP Perske P/N: PERER20W

Shaft Wrench, 1 and 2 HP Perske Motor With 1/2 Collet Capacity. P/N: WRENCH22MM

Face Plate Router Collet Wrench, ER25-M Finger, For Colombo 3 HP Hi-Frequency Motor P/N: ER25-CW

Shaft Wrench, 24MM. P/N: WRENCH24M

Plunge Router Collet Wrench, ER25, For Colombo 7.5 HP Hi-Frequency Motor P/N: COLER25-CW7

Shaft Wrench, 27MM, 7.5 HP Colombo Hi-Fre-quency Motor P/N:WRENCH27MMCounter Rotate Router

Deep Mortise Router Collet Wrench, ER40, For Colombo 11 HP Hi-Frequency Motor, SYIC-04617 P/N:COLER40-CW

Shaft Wrench, 41MM, Open End, For Perske Hi-Frequency Motor PERKRSV61.13-2D P/N:WRENCH041MM

How to Access to Bit Assemblies

1. Turn off all power to the machine. Follow proper lockout/tagout procedures as detailed in the safety section of Chapter 1 of this manual.

Remove and Replace the Router or Pre-Drill Bits

After lockout tagout and access has been obtained to the assemblies, follow these instructions to remove and replace the router bit or the pre-drill bit. See Table 5- 3 on page 5-8 and Table 5- 4 on page 5-9 for a list of recommended tools to use.

Measure Tool Bit Length:

1. Measure from the tip of the bit to the face of the collet. Save this measurement to match to the replacement bit.

Tool Length

Measure the bit length to transfer over to the replacement bit.

Collet



Remove Old Bit

2. Use a collet wrench to remove the bit on the pre-drill or router assemblies.See Fig-ure below.

FIGURE 5- 42. Removing Pre-Drill or Router Bit.

Inspect Collet

3. Inspect and clean collet assembly.

FIGURE 5- 43. Collet Assembly

Collet Wrench

Shaft Wrench

Collet Spindle

Collet Nut

Verify that there is no damage or bluing on the side of the collet



Insert New Bit

4. Lightly attach collet assembly on drill.

5. Insert the new bit into the assembly.

6. Before tightening the collet assembly, adjust the bit depth to the measurement taken in step 1. Ensure there is a minimum of 1/8” clearance from the end of the bit to the bottom of the tool holder.

7. Tighten the collet assembly.

8. Inspect and verify the work. Clean the work area.

If bit is bottomed out the arbor will not tighten and could dam-age the collet or other machine parts.

At Least 1/8” Clearance




About the Automatic Lubricator

The Endeavor contains three self lubricating gear assemblies to lubricate the rails and X motor gears. The self-lubricator is electronic and produces nitrogen gas in the well to increase pressure to push the oil out. The lubricator well sends a replacement alert to the user screen when oil is low (5%). The alert is a 30 day warning, but it is recommended to change it as soon as possible. Refer to Electrical Drawing for connections labels.

FIGURE 5-44. Location of Gear and Lubricator

X Axis Motor

X Axis Gear and Rail

X Axis Gear Applicator

Hose Connection Female

Lubricator Well

Bracket

Low Oil Sensor

Hose Connection Male

Hinge Carriage

Lock Carriage

Grate



Replace the Lubricator Well

The lubricator kit part number is “Wit Lubricating Kit”. It contains, lubricator well, hose (with oil) and its connectors, bracket, and sensor. Follow the instructions on the next page.

FIGURE 5-45. Wit Lubricating Kit

1. Shutdown the machine and follow the Lockout Tagout procedure, in Chapter 1.

2. Prepare to gain access to the X axis motor gear and gear applicator, by removing the grate below the heads.

3. If needed, cut the hose included in the kit to match the one on the machine.

4. Attach the 2 hose connectors to the ends of the new hose.

5. On the new lubricator well, set the dip switches.

6. Disconnect the black and red wires from the machine connector with a small screw-driver.

7. Disconnect the sensor wires from the corresponding node. (Blue to - VDC, Brown to + VDC, Black to input)

Well

Hose

Sensor

Hose Connectors

Clamp

• Remove the protective top from lubri-cator well. Dip switch is located on the top.

• Set the number 5 switch to the “ON” position. This sets Lubricator to a yearly flow cycle.

• Set the number 7 switch to the “ON” position. This turns the Lubricator “ON”

• Ensure the remaining switches are set to “OFF”

ON



8. Loosen the bracket, and remove the well from the side of the machine. Do not dis-card yet.

9. Remove the old hose from the bottom of lubricator well and the applicator.

10. Attach the new hose to the new well and the applicator.

11. Bracket the new well against the machine.

12. Slide the black and red wires into the connector. Secure with a small screw driver.

13. Polarity is not an issue, but for consistency replace wires as they were.

14. Route sensor wires to the corresponding node and connect to the correct terminals.

15. After lubricator well is secured on machine, perform a test run.

16. Verify the oil is being applied to the gear and there is no alert on the user screen. The lubricator well will have blinking light when in operation.

17. Reattach grate and secure wires with a zip tie.


CHAPTER 6 Troubleshooting the Endeavor

This chapter describes troubleshooting steps to help technicians solve issues that may occur with your KVAL machine. If help is needed, call or contact our KVAL Service team at (800) 553-5825 or http://www.kvalinc.com.



About Motion Control This section contains basic information on the operation of motion control circuits. Includes diagrams of the con-trol circuits.

page 6-2

Troubleshooting Basics This section includes basic troubleshooting information. Includes analyzing sub systems to designate a starting point for troubleshooting.

page 6-7

Using Sensors to Troubleshoot

Includes the voltage values of sensors during machine operation.

page 6-10

Troubleshooting Electrical Problems

Includes voltages in the electrical panels, using the Sta-tus Light panel to troubleshoot, and VFD troubleshoot-ing.

page 6-11

Troubleshooting the Air Cylinders

Includes procedure to trouble shoot air cylinders ,such as adjusting extension and retraction speed.

page 6-18

Network System Overview

Includes basic information about the PLC control wiring to different sections in the machine.

page 6-20

Refer to the Air and Electrical drawings provided with delivery of the machine. The drawings are normally located in the Electrical Panel. If copies are unavailable, contact the KVAL Service Department. Have drawings numbers, model number, and serial number of machine read-ily available.

Note:

6-1


About Motion Control


This section describes the positioning systems found in KVAL machinery. There are three basic types of motion control methods used in KVAL Machinery.

Sequencing:

Sequencing is a series of events executed in a predetermined order. Most KVAL machines use a form of sequential motion control. A typical series of events for a KVAL machine are:

1. Move the door into position.

2. Clamp the door.

3. Make the cuts.

4. Unclamp the door.

5. Move the door out.

6. Wait for the next door.

Point to Point:

Point to point motion control involves moving a load from one fixed position to another fixed position at a constant speed and along one line (axis X,Y, or Z). A typical point to point would be a drill with a fixed-depth. The drill is either retracted or extended using a pneumatic cylinder. Typically the drills travel is limited by physical stops.

Incremental:

Incremental motion control is used when the load is required to be moved with high accuracy to multiple locations, sometimes in multiple directions (axes). A typical KVAL usage for this system is a computer controlled router in a door light machine where there is great variety in the cut size, shape and location.

Basic Control Circuit

This section describes a basic control circuit. The Figure below shows a block diagram of a com-mon control circuit. There are four parts to a motion control system:


6-2


FIGURE6- 46. Block Diagram of Basic Motion Control

The User Interface:

• Allows communication between the humans and the machine.

Examples: A touch screen, a PC or a button panel.

The Controller:

• Translates entered information into a form the positioning system can understand.

• Listens to the machine’s other subsystems waiting for the OK to move command.

• Sends the positioning instructions to the positioning system.

• Listens to the positioning system for position status (if there is a feedback loop).

• Tells the machine’s other subsystems when the move process is completed.

Examples: A PLC or a dedicated motion control board.

Positioning System:

• Moves the load.

Examples: A motor or a pneumatic cylinder.

LoadUser InterfaceForce

PositioningSystemTranslated

Positioning

Controller

Instructions

PositioningInstructions(Optional)

Position Feedback(Optional)

Machine’s OtherSubsystems

OK to move

CompleteProcess

The Position Feedback.

• Provides location information to the controller.

Examples: A limit switch, a photo eye, or ferrous eye, a resolver or an encoder

6-3



Typical Positioning Systems

Common Contactor Control

PLCOutput

Fuse(s)

LineVoltage(Power)

Motor

ContactorControl(Coil)Input

PowerInput

PowerOutput

Control CircuitCommon

ON

Should measure Control Voltage120 VAC here

Should measure Line Voltage here



ON

Relay

120 VAC

DC -

Should measure

24 VDC here Control Voltage

Unlike general-purpose relays, contactors are designed to be directly connected to high-current load devices. Contactors are designed to control and suppress the arc pro-duced when interrupting heavy motor currents.The figure below shows a block dia-gram of a typical contactor circuit with typical voltages.

FIGURE 6-47. Block Diagram of a Common Contactor Circuit


6-4


Common Motor Drive Control

An adjustable-speed drive is used to control the motor speed and torque by varying motor input frequency and voltage. A variable-frequency drive (VFD) is used in KVAL machinery. The figure below shows a block diagram of a typical motor drive circuit with typical voltages.

FIGURE6- 48. Block Diagram of a Common Drive Control

Common Motor Drive Control:

PLCOutput

Fuse(s)

LineVoltage

Motor

(Power)

Motor

PowerInput

OutputPower

Control CircuitCommon

ON

Should measure Control Voltage24 VDC here



ON

Drive

STF (Forward)

RL

STR (Revers 2)

SD (COMMON)

OFF

OFF

OFF

Run

300 Run Lightshould be ON

Should display the Motor Frequency

6-5



Typical Positioning System Pneumatic Circuit

A control valve (solenoid) is used to drive cylinders to move different loads in the machine. For Example: extending and retracting router, drill, clamping a door.

FIGURE6- 49. Block Diagram of a Pneumatic Circuit

PLCOutput

HighPressure

Air

Cylinder

CommonControl Circuit

ON

Should measure

24 VDC here Control Voltage

Should have High Pressure air here

ExtendedCylinderRetracted

ControlControl(Coil)Input

AirInput

AirOutput

Valve

Should have High Pressure air on Activated Output


6-6

Troubleshooting Basics


Good trouble shooting starts with looking at the whole machine, where every part is suspect. Then narrowing down the view to the bad part.

Ask: Ask basic questions. For example:

• What was the Machine Trying to Do?

• What Was the Machine Trying to Do Next?

• Was the machine working before?

• Did it happen on first power up or during process?Narrow: Narrow or determine the sequence and subsystem where the issue occurs. For example:

• Did the issue happen when door was being fed in?

• Is the router not cutting?

• Is the cut out of specification?

Note: See Table 6-1 on page 8 for sequence and subsystem information.

Verify: Verify or analyze the subsystem assembly that is responsible for the issue. For example:

• How is the subsystem supposed to work?

• What is keeping the subsystem from working?

Note: See“Analyze the Sub Systems” on page 6-8 for information on verifying and analyzing subsys-tems.

Before you Adjust

Sometimes simple problems can seem to be complex issues. Before making adjustments, check for the following common issues.

1. Is the loaded setup correct for the current cut?

2. Are the stops set up correctly?

3. When did the problem first start?

• At first Start-Up?

• During the Run?

4. When was the last calibration?

5. Is the door true?

6. Use Router Bit Depth Gauge (PN: 432C) to check depth of Bits

7. Check tools for wear.

6-7



Analyze the Sub Systems

1. Check the Load for mechanical issues

• Is the Load “bound up?

• Is there sufficient lubrication?

• Is it an alignment issue?

• Is anything damaged?

2. Check the Position Feed Back.

• Does the Position Feed Back agree with the Load position?

Determine What:

What Subsystem is Respon-sible for the Failed Sequence Step.

Analyze the subsystem:

Check the Load.

Check the Position Feed Back.

Check the Positioning System

See “Analyze the Sub Systems” on page 6-8

TABLE 6-1. Typical KVAL Machine Sequence

Typical Machine Sequence Responsible Subsystem

1. Move Door into Position Feed System

2. Clamp the Door Door Clamp

3. Make the Cuts Cutter Positioning Cutter Power

4. Unclamp the Door Door Clamp

5. Move Door Out Feed System

6. Wait for Next Door Feed System

Basic Troubleshooting Steps

Determine Where:

The Sequence Step Where the Failure Occurs

What was the Machine Trying to Do?

What Was the Machine Trying to Do Next?

Check the Sequences in the Table Below.

How is the Broken Section Suppose to Work?

What is Keeping the Broken Section From Working?

What Part of the Machine is not Working?

Check the Subsystems in the Table Below.

Ask

Narrow

Verify


6-8


In other words are the correct photo eyes, limit switches or ferrous sensors acti-vated? Check the controller inputs to insure the proper sensors are activated. If the controller is a PLC, an activated input is lit. Some touch screens have inputs status also.

3. Common Position Feedback failures:

• Photo Eye: Bad element or bad cable

• Limit Switch: Stuck, or failure

• Wiring: Broken, worn insulation

• PLC: Bad input port.

4. Check the Positioning System

Follow the circuit from the Controller output to the Load and check for component failures.

6-9


Using Sensors to Trouble Shoot

Using Sensors to Trouble Shoot

• Photo Sensors often get dirty. Make sure they are clean. If they are not clean, debris blocks the signal.

• Check output voltages of the sensors in the active mode. The voltage should effec-tively equal 0 VDC

• Check the output voltages of the sensors in inactive mode.The voltage should effec-tively equal 24 VDC


6-10



Refer to Air and Electrical Schematics provided with delivery of the machine. Schematics are located in the Electrical Panel. If copies are unavailable, contact the KVAL Service Department. Have model number and serial number of machine readily available.

NOTE:

The following checks require the electrical panel to be energized. These troubleshooting checks must be per-formed by a Qualified Electrical Technician.

Warning

The electrical component systems are designed to expedite the troubleshooting process and mini-mize “down time”. In general, component systems have the input or feed functions at the top. Output or load functions are positioned at the bottom. Most two-voltage electrical panels are designed with the LOW VOLTAGES on the LEFT, and the HIGH VOLTAGES on the RIGHT. The majority of the system components are labeled with numbers that correspond with the electri-cal prints included in the electrical box door.

Computer controlled machines have signals on the computer that light up when the input or out-put functions are energized, respectively. Computer controlled as well as non-computer controlled machines have white 120V control power terminal strips. This will indicate power supply from the respective circuits.

PLC controllers also have lights on them for the input and output functions. You can easily find out which circuits are failing by watching the lights turn on or off. Compare the lights on the IDEC or Beckhoff controllers to the electrical print to determine what systems are being affected.

If the Power Stops During Normal Operation

1. Check that the input power disconnect switch is not turned off.

2. Check that all of the emergency stop buttons are in the normal position.

3. Check the Six Lights on the Electrical Panel. See “Troubleshooting with the Status Light Panel” on page 6-12.

Lockout and Tagout the main power source.

1. Turn the panel disconnect switch in the off position, open the electrical panel door.

2. Observe the disconnect switches. Look for loose or broken wires at the disconnect then at all of the components.

3. Check for continuity of all fuses with an OHM meter. (Fuses need to be removed from the bottom side of the fuse holder before measuring the fuses)

6-11



Check for Tripped Circuits

1. Remove lock and tag outs on the main power sources.

2. Manually close disconnect sensors and energize the control circuit or transformer with its respective sensor. Check the Status Light Panel,. If all lights are observed, there are no overloads or emergency stops tripped. See” Troubleshooting with the Status Light Panel “below, for more information.

Note: Most electrical problems are related to mechanical malfunction (e.g., stuck motors, jammed chain, blocked photo sensors etc.)

Note: If a solenoid valve is suspected, and not cleared in the air checks section (see), it can be electri-cally jumped to check operation.

Troubleshooting with the Status Light Panel

The Status Light Panel is located on the Electrical Panel. All six lights are illuminated when the system is in proper working order. The lights turn on in a sequence and will stop at the point where a fault is first detected.

4. With the power off, check for motor overloads by pressing each reset button (usu-ally at the bottom of the panel) in SEQUENCE. If one is tripped there will be a slight resistance to touch and a “click” sound as it is reset.

Trip Indicator

Press Reset

Thermal Overload Relay

Test


6-12


If one or more lights are OFF, follow the process below to isolate the cause.

NOTE: Be sure to proceed down the table, starting with the CONTROL POWER light.

STEP 1:Control Power (Amber). If light is OFF go to item A on page 6-14.

STEP 2:Overload Relay (Amber) If light is OFF go to item B on page 6-15.

STEP 3:E-Stop (Amber) If light is OFF go to item C on page 6-15.

STEP 4: Stop (Amber) If light is OFF go to item D on page 6-15.

STEP 5: Start (Amber) If light is OFF go to item E on page 6-16.

STEP 6: 24VDC (Green light is OFF go to item F on page 6-16.

The sequence that the lights turn on are as follows:

1. Control Power (Amber)

2. Overload Relay (Amber)

3. E-Stop (Amber)

4. Stop (Amber)

5. Start (Amber)

6. 24VDC (Green)

6-13



1. Check if the Control Transformer button is pulled out.

4. Is there 110 VAC between #1 & #2 on the 110 VAC Terminal Strip? If not, check the fuse on the output side of the Control Transformer. If fuse is good, check power coming out of Control Transformer.

5. If no power on the output side, and there is power going into the top of the Control Transformer, replace the Control Transformer.

6. If there is power at the Control Transformer, check the wiring of the black and white wire going from the Control Transformer to the 110 VAC Terminal Strip.

2. Is the Disconnect Switch on the main electrical cabinet set to ON?

Switch

3. Is there 208, 220, 440, or 575 VAC to the top side (input) of the Control Trans-former? If not, check the fuses at the Fuse Block, and the contacts on the Control Transformer button on the switch panel.

Input High Vac

Output 110 Vac

Typical Control Transformer

Control Power Light OFF


6-14


E-Stop Light OFF

Check to see the if any E-Stop buttons are pulled out.

NOTE: Location and quantity of E-Stop buttons varies depending on customer need. Typical locations for E-Stop buttons are near the Rear Access Gate and near the Tool Changer Access Gate

Stop Light OFF

Check for 110 VAC between #2 and # If there is volt-age, press the Start button. If no voltage, check the Stop button to make sure it is all the way out and not stuck in, then check the contact to make sure it is closed. If still no voltage, check the wiring.

1. Check Motor Overload Circuits

2. With power on, check the trip indicator LED on the overload. If indicator is orange, press the Reset Button to reset the overload circuit. Retest the Machine.

Overload Relay Light OFF

Contactors

Overload Relays

Reset Button. Fac-tory set on the ''H''

Setting.

Test or Stop

Trip Indicator

Factory Set Current Rating Adjust

6-15



Start Light OFF

If the Start light remains unlit, push in the Start button and hold it in while a second person checks for volt-age between #2 and #5. If there is 110 VAC, replace the ACR relay. If there is no voltage while the button is held in, check the wiring.

First isolate the power supply. Check between DC+ and DC- for 24VDC. If no DC voltage, disconnect the output (V+ and V-) wires from the 24VDC power supply and check for DC voltage where those wires were disconnected.

If no voltage:

Check the input side for 110 VAC. If no 110 VAC, check the fuse. If there is 110 VAC and no 24VDC, replace the 24VDC Power Supply.

If there is 24VDC:

Reconnect the output wires to the 24VDC power supply.

Trace the output wire to the DC terminal block.

Disconnect all (+ 24V positive) wires from the + DC from the DC terminal block except the + output wire from the + 24VDC power supply.

Check for +24VDC at between any –DC and +DC terminal on the DC Terminal block.

Reinstall the (+ 24V positive) wires one by one, checking for +24VDC after installing each. If at any point no voltage is found trace the last reinstalled wire and check for shorts.

Input 110 VAC

Output 24 VDC

24VDC Light OFF


6-16


About VFD Troubleshooting

This section describes some troubleshooting tools for the VFDs.

Error Checking on the Variable Frequency Drives

VFDs (Variable Frequency Drives) interact with hinge and faceplate routers, width adjust motors, and feed motors. If issues occur, error codes are displayed on the VFDs. To help troubleshoot, refer to the VFD manuals located in the High Frequency Panel for lists of the error codes. See “About the Electrical Panels” on page 2-15 for loca-tions of VFDs.

Using the Reset Buttons

In some rare occasions an electrical spike may cause a VFD to shut down. The reset buttons are located on the door of the VFD panels. The button contains the VFD func-tion printed on the button. If a VFD is tripped to “OFF” the button will be lit. To reset a VFD:

1. Push lighted button to reset the indicated motor

c.If the button light turns off, continue with production.

d.If the button stays lit, find the source of the down motor (printed on the but-ton). For example if the feed thru motor is not working, at operator station turn the motor on and off to reset.

e.If issue continues, get the error code off the VFD* and look up the error code in the VFD manual. Follow the instructions in the VFD manual. If issues con-tinue, contact our Service Center. See “Getting Help from KVAL” on page 1-14 .

FIGURE6- 50. VFD Reset Buttons

Note: The number of reset buttons depends on the machine type and option. The figure above shows a machine with 11 VFDs

* The VFD manuals are located in the Electrical Panels. On some machines, documentation can be found in the operation station in the documentation folder.

VFD Reset Buttons

6-17




Most cylinders have an extend and retract port. To adjust the extend motion of a cylinder you must adjust the flow control on the retract port; this regulates the air flow exhausting from the cyl-inder and the opposite is true for the retract motion.

1. Check the air pressure to the machine.

2. Check the flow controls to see that they are adjusted correctly and to the proper specifications.

3. Check for any obstructions to the cylinders such as screws or a misplaced tool etc. FOLLOW ALL SAFETY GUIDELINES AND SIGNS DURING THIS PROCESS.

Manual over-ride button


6-18


4. Check the solenoid air valves:

Once activated, The valve will allow full pressure to cylinder. Make sure you are clear of all moving parts.Caution

a.The solenoid valves can be manually operated by pushing the red manual override button on the end of the valve.

b.If the valve seems to be leaking, the seals may be dry or contaminated with water or it maybe that the cylinder “O” rings are damaged and air is passing from one side to the other side of the cylinder which means the air is exhaust-ing through the solenoid valve. It maybe is necessary to purchase a rebuild kit or a new cylinder.

c.If the valve is not receiving an electrical signal, for instructions. It might be necessary to call in a specialist or check with KVAL customer service at 1-800-553-5825.

5. If an Air Leak is coming from an exhaust port on the solenoid air bank:

a.Check the solenoid for the manual override. If the solenoid has a manual over-ride you can push each of the buttons one at a time. When the air leak stops or weakens it usually means that one or more of the cylinders that the solenoid is operating are faulty.

6-19



Adjusting Cylinder Extension Speed:

NO

Adjusting Cylinder Retraction Speed:

NO


6-20



A PLC (Programmable Logic Control) controls the Endeavor. The PLC can process multiple ana-log and digital inputs, and output arrangements. The system can handle extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.

The PLC is located in the Main Electrical Panel. From the PLC, connections are made to coupler interfaces located near the sections they control. See your machine’s schematic package for detailed wiring information.

Connections to Servo Drives

The Servo Drives are located in the Main Electrical Panel. The outputs connect to the servo motors of carious assemblies. They may include:

• The Head X, Y and Z motors

• Feed motors

• Back section location X, Y, and Z motors.For detailed wiring information, see your machine’s electrical drawings.

Connections to VFD’s (High Freq Panel)

The Servo Drives are located in the Main Electrical Panel. The outputs connect to the motors to drive assemblies, such as:

• Front Routers

• Face Plate Router

• Pre-Drills

• Feeder

• Width Adjust For detailed wiring information, see your machine’s electrical drawings.

6-21




6-22

Index
Numerics110V / 24 V terminals
location electrical panels2-16

AAbort Job2-29adjustment menus

how to use3-5air input system

description5-5lubricator5-5

air line lubricatoradjusting5-6priming5-6

air line lubricator, maintenance schedule5-3air valve

lockout tagout1-10

Bback section

key assemblies2-10back section group

description2-31back section status

feedback2-27ball screw, maintenance schedule5-3base

readout description3-5Beckhoff® CPU module4-2bit assemblies

how to access5-8bits

replacing5-7

CCalibration

about the tabs3-3enter a positive of negative number?3-4entering data3-5how to make a reference cut3-18menus

reference cutsbefore you calibrate3-2

process to make a reference cut3-19

unlock3-4Chisel (lock)

adjustments3-13Chisels

about calibration3-10chisels

replacing5-7Clear Remaining Quantity2-29collet assembly

inspection5-10computer

as a PLC4-2backing up4-2, 4-3

contact information1-2control panel light

not on? troubleshoot6-14control power indicator light description2-17control transformer switch

power up2-21, 2-22Counter Rotate Router

adjustments3-11customer service1-2

DDeep Mortise

adjustments3-16description2-27Door Feed

menu map3-6Door Feelers

how to adjust3-6process to adjust3-7

Door Length Feelersdescription of2-4

Door Stopsdescription of in feed and out feed stops2-4

drill bitreplacing5-7

dura-lith grease, bearing lube5-3DVI/USB module location4-2

Eelectrical panels

description2-15emergency shutdown

KVAL Endeavor Operation / Service Manual 1

2

description2-23Endeavor

description of machine2-2e-stop light

description2-17EtherCat®

smart power supply4-2terminals,location4-2

ethernet moduleconnection to servo amplifiers4-2

FFeed Mode2-30flange block bearing, maintenance schedule5-3front section

key assemblies2-8, 2-10front section status

feedback2-27

Ggear box, maintenance schedule5-3

HHead Axes

about calibration3-8Head Axis

adjustments3-9Head Axis (lock)

adjustments3-13high frequency panel

description2-15high voltage

electrical panel2-16Hinge Head

menu map3-8reference cut dimensions3-18

Hinge Routeradjustments3-11

hinge spec groupdescription2-31

home buttonusing2-22

Home Machine2-29

Iinductive proximity sensor2-17In-Feed Section

description2-3in-feed section

key assemblies2-2input and output terminals

location electrical panels2-16internet access

location of connection4-2remote connection4-2RJ45 to intranet4-2

intranetRJ45 connection4-2

KKVAL, getting help1-14

LLCD display

smart power supply4-2linear bearing, maintenance schedule5-3location2-27location of Door Length Feeler2-4Lock Head

reference cut dimensions3-18Lock Head Calibration

menu map3-12lockout and tagout Guidelines1-10lockout procedure1-9log screen

description2-36

MMachine Feed Back2-27machine feed back

user output2-27machine feedback

front section status2-27general2-27servo positons2-27

machine statusgeneral feedback2-27

main electrical paneldescription2-15

KVAL Endeavor Operation / Service Manual

main screeninterface2-28

maintenancedaily5-2six month5-2weekly5-2

Manual Feed Control2-30manual operation

interface2-34menu map2-26

Nnetwork system

overview6-20

OOperator’s Tour2-2operator’s tour

top view2-2out-feed

key assemblies2-14overload relay light description2-17

Ppart number ,manual1-4pillow block bearing, maintenance schedule5-3PLC

battery location4-2connections4-2location4-2

Plunge Router (lock)adjustments3-16

powerdisconnect switches1-9lock out procedure1-9

power uptroubleshooting6-11

poweringup and down machine2-21

pre-drill bitusing tool to set depth5-11

pre-drill bitsreplacing5-9

Predrill Parameters2-33Predrill Tab2-32

preset selectiondescription2-30

process defined2-3product return procedure1-14programmable logic controller,PLC4-2

RReference Cut

about3-18process steps3-19

remote operation, setting up machine for1-16reset machine button

description user interface2-29Restore Points

createload

delete3-5return material authorization (RMA)1-14returning the product to Kval1-14Right Hand Rule3-4Router (lock)

adjustments3-15router bit

replacing5-7Routine Speed Percent2-31

SSafe Mode Enabled/Disabled2-29safety guidelines1-5Safety Sign Off Sheet

Safety Concerns1-19sensors

troubleshooing6-10types2-17voltage levels2-18

serviceconnecting your machine to KVAL Service4-3

service center, contacting information1-14servo drives

connectionslocation6-20

location in main electrical panel2-16servo positions

feedback2-27

KVAL Endeavor Operation / Service Manual 3

4

setup hingesgroup location2-32

six light paneldescription2-16sequence list2-16

start lightdescription6-16

start light description2-17start machine button

power up2-21Start Sequence2-29status light panel

description6-12use as troubleshooting key6-12

Stop Downloads2-29stop light description2-17

Ttagout procedure1-9templates

global vs. tenant2-43Toggle Clamp2-31Toggle Stop2-31troubleshooting

air cylinders6-18using status lights6-13

TwinCAT 2® software automation software4-2

UUSB module4-2user interface screens

description2-25

VVTD

location in high frequency panel2-16

WWidth

how to adjust3-6Width Adjust2-30Windows CE® operating system,about4-2

Zzerk fittings5-4

locations5-4zero-energy start-up

clean up1-12inspect1-12

KVAL Endeavor Operation / Service Manual


Customer Service

Mailing address:

Customer Support Department

Kval Incorporated

825 Petaluma Boulevard South

Petaluma, CA 94952

Contacting KVAL

Phone and Fax:

In the U.S and Canada, call (800) 553-5825 or fax (707) 762-0485

Outside the U.S. and Canada, call (707) 762-7367 or fax (707) 762-0485

Email: [email protected]


endeavor door system - kval inc

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